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Search Results (624)

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Keywords = high-power laser systems

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17 pages, 1738 KiB  
Article
Evaluation of Optimal Visible Wavelengths for Free-Space Optical Communications
by Modar Dayoub and Hussein Taha
Telecom 2025, 6(3), 57; https://doi.org/10.3390/telecom6030057 - 4 Aug 2025
Viewed by 54
Abstract
Free-space optical (FSO) communications have emerged as a promising complement to conventional radio-frequency (RF) systems due to their high bandwidth, low interference, and license-free spectrum. Visible-light FSO communication, using laser diodes or LEDs, offers potential for short-range data links, but performance is highly [...] Read more.
Free-space optical (FSO) communications have emerged as a promising complement to conventional radio-frequency (RF) systems due to their high bandwidth, low interference, and license-free spectrum. Visible-light FSO communication, using laser diodes or LEDs, offers potential for short-range data links, but performance is highly wavelength-dependent under varying atmospheric conditions. This study presents an experimental evaluation of three visible laser diodes at 650 nm (red), 532 nm (green), and 405 nm (violet), focusing on their optical output power, quantum efficiency, and modulation behavior across a range of driving currents and frequencies. A custom laboratory testbed was developed using an Atmega328p microcontroller and a Visual Basic control interface, allowing precise control of current and modulation frequency. A silicon photovoltaic cell was employed as the optical receiver and energy harvester. The results demonstrate that the 650 nm red laser consistently delivers the highest quantum efficiency and optical output, with stable performance across electrical and modulation parameters. These findings support the selection of 650 nm as the most energy-efficient and versatile wavelength for short-range, cost-effective visible-light FSO communication. This work provides experimentally grounded insights to guide wavelength selection in the development of energy-efficient optical wireless systems. Full article
(This article belongs to the Special Issue Optical Communication and Networking)
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20 pages, 2399 KiB  
Article
Exploring Novel Optical Soliton Molecule for the Time Fractional Cubic–Quintic Nonlinear Pulse Propagation Model
by Syed T. R. Rizvi, Atef F. Hashem, Azrar Ul Hassan, Sana Shabbir, A. S. Al-Moisheer and Aly R. Seadawy
Fractal Fract. 2025, 9(8), 497; https://doi.org/10.3390/fractalfract9080497 - 29 Jul 2025
Viewed by 321
Abstract
This study focuses on the analysis of soliton solutions within the framework of the time-fractional cubic–quintic nonlinear Schrödinger equation (TFCQ-NLSE), a powerful model with broad applications in complex physical phenomena such as fiber optic communications, nonlinear optics, optical signal processing, and laser–tissue interactions [...] Read more.
This study focuses on the analysis of soliton solutions within the framework of the time-fractional cubic–quintic nonlinear Schrödinger equation (TFCQ-NLSE), a powerful model with broad applications in complex physical phenomena such as fiber optic communications, nonlinear optics, optical signal processing, and laser–tissue interactions in medical science. The nonlinear effects exhibited by the model—such as self-focusing, self-phase modulation, and wave mixing—are influenced by the combined impact of the cubic and quintic nonlinear terms. To explore the dynamics of this model, we apply a robust analytical technique known as the sub-ODE method, which reveals a diverse range of soliton structures and offers deep insight into laser pulse interactions. The investigation yields a rich set of explicit soliton solutions, including hyperbolic, rational, singular, bright, Jacobian elliptic, Weierstrass elliptic, and periodic solutions. These waveforms have significant real-world relevance: bright solitons are employed in fiber optic communications for distortion-free long-distance data transmission, while both bright and dark solitons are used in nonlinear optics to study light behavior in media with intensity-dependent refractive indices. Solitons also contribute to advancements in quantum technologies, precision measurement, and fiber laser systems, where hyperbolic and periodic solitons facilitate stable, high-intensity pulse generation. Additionally, in nonlinear acoustics, solitons describe wave propagation in media where amplitude influences wave speed. Overall, this work highlights the theoretical depth and practical utility of soliton dynamics in fractional nonlinear systems. Full article
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22 pages, 6689 KiB  
Article
Design and Implementation of a Sun Outage Simulation System with High Uniformity and Stray Light Suppression Capability
by Zhen Mao, Zhaohui Li, Yong Liu, Limin Gao and Jianke Zhao
Sensors 2025, 25(15), 4655; https://doi.org/10.3390/s25154655 - 27 Jul 2025
Viewed by 368
Abstract
To enable accurate evaluation of satellite laser communication terminals under solar outage interference, this paper presents the design and implementation of a solar radiation simulation system targeting the 1540–1560 nm communication band. The system reconstructs co-propagating interference conditions through standardized and continuously tunable [...] Read more.
To enable accurate evaluation of satellite laser communication terminals under solar outage interference, this paper presents the design and implementation of a solar radiation simulation system targeting the 1540–1560 nm communication band. The system reconstructs co-propagating interference conditions through standardized and continuously tunable output, based on high irradiance and spectral uniformity. A compound beam homogenization structure—combining a multimode fiber and an apodizator—achieves 85.8% far-field uniformity over a 200 mm aperture. A power–spectrum co-optimization strategy is introduced for filter design, achieving a spectral matching degree of 78%. The system supports a tunable output from 2.5 to 130 mW with a 50× dynamic range and maintains power control accuracy within ±0.9%. To suppress internal background interference, a BRDF-based optical scattering model is established to trace primary and secondary stray light paths. Simulation results show that by maintaining the surface roughness of key mirrors below 2 nm and incorporating a U-shaped reflective light trap, stray light levels can be reduced to 5.13 × 10−12 W, ensuring stable detection of a 10−10 W signal at a 10:1 signal-to-background ratio. Experimental validation confirms that the system can faithfully reproduce solar outage conditions within a ±3° field of view, achieving consistent performance in spectrum shaping, irradiance uniformity, and background suppression. The proposed platform provides a standardized and practical testbed for ground-based anti-interference assessment of optical communication terminals. Full article
(This article belongs to the Section Communications)
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22 pages, 2422 KiB  
Article
OSIRIS4CubeSat—The World’s Smallest Commercially Available Laser Communication Terminal
by Benjamin Rödiger, Christian Roubal, Fabian Rein, René Rüddenklau, Anil Morab Vishwanath and Christopher Schmidt
Aerospace 2025, 12(8), 655; https://doi.org/10.3390/aerospace12080655 - 23 Jul 2025
Viewed by 232
Abstract
The New Space movement led to an exponential increase in the number of the smallest satellites in orbit in the last two decades. The number of required communication channels increased with that as well and revealed the limitations of classical radio frequency channels. [...] Read more.
The New Space movement led to an exponential increase in the number of the smallest satellites in orbit in the last two decades. The number of required communication channels increased with that as well and revealed the limitations of classical radio frequency channels. Free-space optical communication overcomes these challenges and has been successfully demonstrated, with operational systems in orbit on large and small satellites. The next step is to miniaturize the technology of laser communication to make it usable on CubeSats. Thus, the German Aerospace Center (DLR) developed, together with Tesat-Spacecom GmbH & Co. KG in Backnang, Germany, a highly miniaturized and power-efficient laser terminal, which is based on a potential customer’s use case. OSIRIS4CubeSat uses a new patented design that combines electronics and optomechanics into a single system architecture to achieve a high compactness following the CubeSat standard. Interfaces and software protocols that follow established standards allowed for an easy transition to the industry for a commercial mass market. The successful demonstration of OSIRIS4CubeSat during the PIXL-1 mission proved its capabilities and the advantages of free-space optical communication in the final environment. This paper gives an overview of the system architecture and the development of the single subsystems. The system’s capabilities are verified by the already published in-orbit demonstration results. Full article
(This article belongs to the Special Issue On-Board Systems Design for Aerospace Vehicles (2nd Edition))
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13 pages, 2390 KiB  
Article
Enhancing Laser Damage Resistance in TiO2 Films: Dual-Additive Strategy Using High Thermal Conductivity Agents and Long-Chain Organic Compounds
by Yan Zhang, Ming Ma, Zirun Peng, Na Liu, Hanzhuo Zhang, Peizhong Feng and Cheng Xu
Photonics 2025, 12(8), 742; https://doi.org/10.3390/photonics12080742 - 22 Jul 2025
Viewed by 208
Abstract
The laser damage resistance of optical films holds significant practical importance, as it largely determines both the maximum power output of laser systems and the overall stability of the entire optical assembly. A comprehensive investigation was conducted to examine the influence of both [...] Read more.
The laser damage resistance of optical films holds significant practical importance, as it largely determines both the maximum power output of laser systems and the overall stability of the entire optical assembly. A comprehensive investigation was conducted to examine the influence of both single additives—acetylacetone (ACAC) and diethanolamine (DEA)—and dual-additive systems, specifically ACAC combined with polyethylene glycol 200 (PEG 200) and DEA combined with PEG 200, on TiO2 film properties and their laser-induced damage behavior under 1064 nm irradiation. It demonstrated that the films fabricated using ACAC exhibited smoother surfaces. Nevertheless, the sol prepared with DEA was more stable, resulting in films with superior optical properties and an enhanced laser-induced damage threshold (LIDT). The incorporation of dual additives further improved the films’ LIDT. Specifically, the film with DEA and PEG 200 achieved the highest LIDT, reaching 21.5 J/cm2. Moreover, all films exhibited defect-induced damage, yet distinct damage morphologies were observed across different samples. The single-additive films predominantly displayed stress-type damage patterns, whereas the dual-additive films manifested melting-type damage characteristics. Furthermore, through a combination of experiments and calculations, it was revealed that the reasons why the film with DEA and PEG 200 achieved the highest LIDT were twofold: first, the high thermal conductivity of DEA reduced the maximum temperature at the defect center within the film; second, the long molecular chains of PEG 200 created a looser film structure that better mitigated damage caused by stress and expansion during laser irradiation. This study presents a promising approach to enhancing the LIDT through the strategic selection of additives with high thermal conductivity while simultaneously incorporating organic compounds with long molecular chains to develop effective dual-additive films. Full article
(This article belongs to the Section Lasers, Light Sources and Sensors)
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33 pages, 112557 KiB  
Article
Enhanced Tumor Diagnostics via Cyber-Physical Workflow: Integrating Morphology, Morphometry, and Genomic MultimodalData Analysis and Visualization in Digital Pathology
by Marianna Dimitrova Kucarov, Niklolett Szakállas, Béla Molnár and Miklos Kozlovszky
Sensors 2025, 25(14), 4465; https://doi.org/10.3390/s25144465 - 17 Jul 2025
Viewed by 367
Abstract
The rapid advancement of genomic technologies has significantly transformed biomedical research and clinical applications, particularly in oncology. Identifying patient-specific genetic mutations has become a crucial tool for early cancer detection and personalized treatment strategies. Detecting tumors at the earliest possible stage provides critical [...] Read more.
The rapid advancement of genomic technologies has significantly transformed biomedical research and clinical applications, particularly in oncology. Identifying patient-specific genetic mutations has become a crucial tool for early cancer detection and personalized treatment strategies. Detecting tumors at the earliest possible stage provides critical insights beyond traditional tissue analysis. This paper presents a novel cyber-physical system that combines high-resolution tissue scanning, laser microdissection, next-generation sequencing, and genomic analysis to offer a comprehensive solution for early cancer detection. We describe the methodologies for scanning tissue samples, image processing of the morphology of single cells, quantifying morphometric parameters, and generating and analyzing real-time genomic metadata. Additionally, the intelligent system integrates data from open-access genomic databases for gene-specific molecular pathways and drug targets. The developed platform also includes powerful visualization tools, such as colon-specific gene filtering and heatmap generation, to provide detailed insights into genomic heterogeneity and tumor foci. The integration and visualization of multimodal single-cell genomic metadata alongside tissue morphology and morphometry offer a promising approach to precision oncology. Full article
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10 pages, 1296 KiB  
Article
High-Sensitivity Dynamic Detection of Dissolved Acetylene in Transformer Oil Based on High-Power Quartz-Enhanced Photoacoustic Spectroscopy Sensing System
by Yuxiang Wu, Tiehua Ma, Chenhua Liu, Yashan Fan, Shuai Shi, Songjie Guo, Yu Wang, Xiangjun Xu, Guqing Guo, Xuanbing Qiu, Zhijin Shang and Chuanliang Li
Photonics 2025, 12(7), 713; https://doi.org/10.3390/photonics12070713 - 16 Jul 2025
Viewed by 281
Abstract
To enable the highly sensitive detection of acetylene (C2H2) dissolved in transformer oil, a high-power quartz-enhanced photoacoustic spectroscopy (QEPAS) sensing system is proposed. A standard 32.7 kHz quartz tuning fork (QTF) was employed as an acoustic transducer, coupled with [...] Read more.
To enable the highly sensitive detection of acetylene (C2H2) dissolved in transformer oil, a high-power quartz-enhanced photoacoustic spectroscopy (QEPAS) sensing system is proposed. A standard 32.7 kHz quartz tuning fork (QTF) was employed as an acoustic transducer, coupled with an optimized acoustic resonator to enhance the acoustic signal. The laser power was boosted to 150 mW using a C-band erbium-doped fiber amplifier (EDFA), achieving a detection limit of 469 ppb for C2H2 with an integration time of 1 s. The headspace degassing method was utilized to extract dissolved gases from the transformer oil, and the equilibrium process for the release of dissolved C2H2 was successfully monitored using the developed high-power QEPAS system. This approach provides reliable technical support for the real-time monitoring of the operational safety of power transformers. Full article
(This article belongs to the Section Lasers, Light Sources and Sensors)
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12 pages, 1896 KiB  
Article
A 6 kW Level Linearly Polarized Near-Diffraction-Limited Monolithic Fiber Laser with a 0.43 nm Linewidth
by Zixiang Gao, Qiang Shu, Fang Li, Chun Zhang, Fengyun Li, Xingchen Jiang, Yu Wen, Cheng Chen, Li Li, Qiuhui Chu, Rumao Tao, Honghuan Lin, Zhitao Peng and Jianjun Wang
Photonics 2025, 12(7), 701; https://doi.org/10.3390/photonics12070701 - 11 Jul 2025
Viewed by 406
Abstract
A high-power, narrow-linewidth, all-fiber polarization-maintaining (PM) amplifier has been demonstrated. A lasing power of 5870 W has been delivered in master oscillator power amplifier architecture with cascaded white noise source (WNS) phase modulation and bidirectional pumping schemes. The maximal power was limited by [...] Read more.
A high-power, narrow-linewidth, all-fiber polarization-maintaining (PM) amplifier has been demonstrated. A lasing power of 5870 W has been delivered in master oscillator power amplifier architecture with cascaded white noise source (WNS) phase modulation and bidirectional pumping schemes. The maximal power was limited by the onset of stimulated Brillouin scattering. At the maximum power operation, the amplifier exhibited a 3 dB spectral linewidth of 0.43 nm with beam quality being M2 < 1.33 and polarization extinction ratio (PER) being 16.3 dB. To the best of our knowledge, this represents the highest spectral brightness and PER achieved by PM fiber laser systems around 6 kW-level operation. Full article
(This article belongs to the Special Issue High-Power Fiber Lasers)
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22 pages, 5129 KiB  
Article
A Dynamic Analysis of a Cantilever Piezoelectric Vibration Energy Harvester with Maximized Electric Polarization Due to the Optimal Shape of the Thickness for First Eigen Frequency
by Paulius Skėrys and Rimvydas Gaidys
Appl. Sci. 2025, 15(13), 7525; https://doi.org/10.3390/app15137525 - 4 Jul 2025
Viewed by 304
Abstract
This study presents an analytical and experimental approach to enhance cantilever-based piezoelectric energy harvesters by optimizing thickness distribution. Using a gradient projection algorithm within a state-space framework, the unimorph beam’s geometry is tailored while constraining the first natural frequency. The objective is to [...] Read more.
This study presents an analytical and experimental approach to enhance cantilever-based piezoelectric energy harvesters by optimizing thickness distribution. Using a gradient projection algorithm within a state-space framework, the unimorph beam’s geometry is tailored while constraining the first natural frequency. The objective is to amplify axial strain within the piezoelectric layers, thereby increasing electric polarization and maximizing the conversion efficiency of mechanical vibrations into electrical energy. The steady-state response under harmonic base excitation at resonance was modeled to evaluate the harvester’s dynamic behavior against uniform-thickness counterparts. Results show that the optimized beam achieves significantly higher output voltage and energy harvesting efficiency. Simulations reveal effective strain concentration in regions of high piezoelectric sensitivity, enhancing power generation under resonant conditions. Two independent experimental setups were employed for empirical validation: a non-contact laser vibrometry system (Polytec 3D) and a first resonant base excitation setup. Eigenfrequencies matched within 5% using a Polytec multipath interferometry system, and constant excitation tests showed approximately 30% higher in optimal shapes electrical potential value generation. The outcome of this study highlights the efficacy of geometric tailoring—specifically, non-linear thickness shaping—as a key strategy in achieving enhanced energy output from piezoelectric harvesters operating at their fundamental frequency. This work establishes a practical route for optimizing unimorph structures in real-world applications requiring efficient energy capture from low-frequency ambient vibrations. Full article
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14 pages, 4193 KiB  
Article
Comparative Analysis of Two Types of Combined Power-Over-Fiber and Radio-Over-Fiber Systems Using Raman Amplification for Different Link Lengths
by Paulo Kiohara, Romildo H. Souza, Véronique Quintard, Mikael Guegan, Laura Ghisa, André Pérennou and Olympio L. Coutinho
Sensors 2025, 25(13), 4159; https://doi.org/10.3390/s25134159 - 4 Jul 2025
Viewed by 330
Abstract
The use of analog radio-over-fiber (RoF) systems combined with power-over-fiber (PoF) systems has been proposed in recent years for applications involving remote sensors used in hazardous environments or where electrical wiring may be impractical. This article presents a hybrid architecture topology that combines [...] Read more.
The use of analog radio-over-fiber (RoF) systems combined with power-over-fiber (PoF) systems has been proposed in recent years for applications involving remote sensors used in hazardous environments or where electrical wiring may be impractical. This article presents a hybrid architecture topology that combines PoF and RoF, using Raman amplification to obtain RF gain. The first emphasis is placed on the use of two types of high-power laser sources (HPLSs) for the PoF system: a 1480 nm Raman-based HPLS and a 1550 nm HPLS that is based on an erbium-doped fiber amplifier (EDFA). The second emphasis of this paper is on how these two HPLSs simulate Raman scattering (SRS) in the fiber, considering different lengths of SMF 28 for the link. Thus, a comparative analysis is proposed considering the effects induced on the RF signal, mainly focused on its RF power gain (GRF), noise figure (NF), and spurious-free dynamic range (SFDR). The obtained results show that the architecture using a PoF system based on the 1550 nm HPLS benefits from a lower noise figure degradation, even when the noise generated by the optical amplification is considered. Full article
(This article belongs to the Special Issue Optical Communications in Sensor Networks)
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27 pages, 61752 KiB  
Article
Knowledge Generation of Wire Laser-Beam-Directed Energy Deposition Process Combining Process Data and Metrology Responses
by Adriano Nicola Pilagatti, Eleonora Atzeni, Alessandro Salmi, Konstantinos Tzimanis, Nikolas Porevopoulos and Panagiotis Stavropoulos
J. Manuf. Mater. Process. 2025, 9(7), 230; https://doi.org/10.3390/jmmp9070230 - 3 Jul 2025
Viewed by 557
Abstract
Industries are leveraging the wire laser-beam-directed energy deposition (DED-LB) additive manufacturing (AM) process to manufacture and repair high-quality, defect-free, and cost-effective parts. However, expensive, non-easily accessible, and complex metrology equipment is needed to quantify part-related performance metrics such as cross-sectional dimensional accuracy and [...] Read more.
Industries are leveraging the wire laser-beam-directed energy deposition (DED-LB) additive manufacturing (AM) process to manufacture and repair high-quality, defect-free, and cost-effective parts. However, expensive, non-easily accessible, and complex metrology equipment is needed to quantify part-related performance metrics such as cross-sectional dimensional accuracy and intrinsic defects. This information is necessary for establishing the operating process window and for the quality characterization of the part. Therefore, this work presents a methodology that combines information captured from a vision-based monitoring system with the output of Computed Tomography (CT) towards the knowledge generation and process optimization of wire DED-LB. The design of experiments as well as the interpretation of the results are achieved by employing Nested ANOVA where the dependency of cross-sectional stability on the laser power parameter is demonstrated, enabling, at the same time, the understanding of unstructured datasets where multiple parameters vary at different levels. Finally, this work can be the pillar for adopting new production and part requirements while also giving directions about the effect of control strategies on the part quality. Full article
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16 pages, 3101 KiB  
Article
Enhanced High-Resolution and Long-Range FMCW LiDAR with Directly Modulated Semiconductor Lasers
by Luís C. P. Pinto and Maria C. R. Medeiros
Sensors 2025, 25(13), 4131; https://doi.org/10.3390/s25134131 - 2 Jul 2025
Viewed by 622
Abstract
Light detection and ranging (LiDAR) sensors are essential for applications where high-resolution distance and velocity measurements are required. In particular, frequency-modulated continuous wave (FMCW) LiDAR, compared with other LiDAR implementations, provides superior receiver sensitivity, enhanced range resolution, and the capability to measure velocity. [...] Read more.
Light detection and ranging (LiDAR) sensors are essential for applications where high-resolution distance and velocity measurements are required. In particular, frequency-modulated continuous wave (FMCW) LiDAR, compared with other LiDAR implementations, provides superior receiver sensitivity, enhanced range resolution, and the capability to measure velocity. Integrating LiDARs into electronic and photonic semiconductor chips can lower their cost, size, and power consumption, making them affordable for cost-sensitive applications. Additionally, simple designs are required, such as FMCW signal generation by the direct modulation of the current of a semiconductor laser. However, semiconductor lasers are inherently nonlinear, and the driving waveform needs to be optimized to generate linear FMCW signals. In this paper, we employ pre-distortion techniques to compensate for chirp nonlinearity, achieving frequency nonlinearities of 0.0029% for the down-ramp and the up-ramp at 55 kHz. Experimental results demonstrate a highly accurate LiDAR system with a resolution of under 5 cm, operating over a 210-m range through single-mode fiber, which corresponds to approximately 308 m in free space, towards meeting the requirements for long-range autonomous driving. Full article
(This article belongs to the Special Issue Feature Papers in Optical Sensors 2025)
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10 pages, 2216 KiB  
Article
A Solid-State Three-Stage Nd:YVO4 Laser Amplifier System Based on AOM Pulse Picker-Integrated Modulator
by Zhenyu Li, Yawen Zheng, Zhengtao Zhang, Peipei Lu, Zhen Zeng, Zhongsheng Zhai and Boya Xie
Quantum Beam Sci. 2025, 9(3), 22; https://doi.org/10.3390/qubs9030022 - 1 Jul 2025
Viewed by 311
Abstract
In recent years, ultrafast bursts with high power have been applied in many significant fields. However, the peak power of the pulse train generated by fiber lasers is limited by fiber characteristics from nonlinear effects, which can only be at the level of [...] Read more.
In recent years, ultrafast bursts with high power have been applied in many significant fields. However, the peak power of the pulse train generated by fiber lasers is limited by fiber characteristics from nonlinear effects, which can only be at the level of milliwatt. In this research, the pulse frequency is reduced by an AOM pulse picker-integrated modulator. With M2 and pulse width guaranteed, the frequency of the reduced pulse train is amplified by a solid-state three-stage Nd:YVO4 amplifier system. Finally, the peak power of the pulse train is increased. The final output pulse repetition rate of the experiment is 1 MHz with a pulse width of 8.09 picoseconds and a peak power of up to 3.7 MW. Full article
(This article belongs to the Section High-Power Laser Physics)
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18 pages, 4806 KiB  
Article
Laser Powder Bed Fusion Additive Manufacturing of a CoCrFeNiCu High-Entropy Alloy: Processability, Microstructural Insights, and (In Situ) Mechanical Behavior
by Vito Burgio and Ghazal Moeini
Materials 2025, 18(13), 3071; https://doi.org/10.3390/ma18133071 - 27 Jun 2025
Viewed by 417
Abstract
High-entropy alloys are known for their promising mechanical properties, wear and corrosion resistance, which are maintained across a wide range of temperatures. In this study, a CoCrFeNiCu-based high-entropy alloy, distinguished from conventional CoCrFeNi systems by the addition of Cu, which is known to [...] Read more.
High-entropy alloys are known for their promising mechanical properties, wear and corrosion resistance, which are maintained across a wide range of temperatures. In this study, a CoCrFeNiCu-based high-entropy alloy, distinguished from conventional CoCrFeNi systems by the addition of Cu, which is known to enhance toughness and wear resistance, was investigated to better understand the effects of compositional modification on processability and performance. The influence of key process parameters, specifically laser power and scan speed, on the processability of CoCrFeNiCu-based high-entropy alloys produced by laser powder bed fusion additive manufacturing was investigated, with a focus of low laser power, which is critical for minimizing defects and improving the resulting microstructure and mechanical performance. The printed sample density gradually increases with higher volumetric energy density, achieving densities exceeding 99.0%. However, at higher energy densities, the samples exhibit susceptibility to hot cracking, an issue that cannot be mitigated by adjusting the process parameters. Mechanical properties under optimized parameters were further evaluated using Charpy impact and (in situ) tensile tests. These evaluations were supplemented by in situ tensile experiments conducted within a scanning electron microscope to gain insights into the behavior of defects, such as hot cracks, during tensile testing. Despite the sensitivity to hot cracking, the samples exhibited a respectable ultimate tensile strength of 662 MPa, comparable to fine-grained steels like S500MC (070XLK). These findings underscore the potential of CoCrFeNiCu-based high-entropy alloys for advanced applications. However, they also highlight the necessity for developing strategies to ensure stable and reliable processing methods that can mitigate the susceptibility to hot cracking. Full article
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19 pages, 4360 KiB  
Article
A Feasibility Study on UV Nanosecond Laser Ablation for Removing Polyamide Insulation from Platinum Micro-Wires
by Danial Rahnama, Graziano Chila and Sivakumar Narayanswamy
J. Manuf. Mater. Process. 2025, 9(7), 208; https://doi.org/10.3390/jmmp9070208 - 21 Jun 2025
Cited by 1 | Viewed by 587
Abstract
This study presents the optimization of a laser ablation process designed to achieve the precise removal of polyamide coatings from ultra-thin platinum wires. Removing polymer coatings is a critical challenge in high-reliability manufacturing processes such as aerospace thermocouple fabrication. The ablation process must [...] Read more.
This study presents the optimization of a laser ablation process designed to achieve the precise removal of polyamide coatings from ultra-thin platinum wires. Removing polymer coatings is a critical challenge in high-reliability manufacturing processes such as aerospace thermocouple fabrication. The ablation process must not only ensure the complete removal of the polyamide insulation but also maintain the tensile strength of the wire to withstand mechanical handling in subsequent manufacturing stages. Additionally, the exposed platinum surface must exhibit low surface roughness to enable effective soldering and be free of thermal damage or residual debris to pass strict visual inspections. The wires have a total diameter of 65 µm, consisting of a 50 µm platinum core encased in a 15 µm polyamide coating. By utilizing a UV laser with a wavelength of 355 nm, average power of 3 W, a repetition rate range of 20 to 200 kHz, and a high-speed marking system, the process parameters were systematically refined. Initial attempts to perform the ablation in an air medium were unsuccessful due to inadequate thermal control and incomplete removal of the polyamide coating. Hence, a water-assisted ablation technique was explored to address these limitations. Experimental results demonstrated that a scanning speed of 1200 mm/s, coupled with a line spacing of 1 µm and a single ablation pass, resulted in complete coating removal while ensuring the integrity of the platinum substrate. The incorporation of a water layer above the ablation region was considered crucial for effective heat dissipation, preventing substrate overheating and ensuring uniform ablation. The laser’s spot diameter of 20 µm in air and a focal length of 130 mm introduced challenges related to overlap control between successive passes, requiring precise calibration to maintain consistency in coating removal. This research demonstrates the feasibility and reliability of water-assisted laser ablation as a method for a high-precision, non-contact coating material. Full article
(This article belongs to the Special Issue Advances in Laser-Assisted Manufacturing Techniques)
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