Search Results (547)

Carbon deposits on the crown of engine pistons can markedly reduce combustion efficiency and shorten service life. Conventional cleaning techniques often fail to simultaneously ensure a high carbon removal efficiency and maintain optimal surface integrity. To enable efficient and precise carbon removal, this study proposes the application of hybrid laser cleaning—combining continuous-wave (CW) and pulsed lasers—to piston carbon deposit removal, and employs response surface methodology (RSM) for multi-objective process optimization. Using the N52B30 engine piston as the experimental substrate, this study systematically investigates the combined effects of key process parameters—including CW laser power, pulsed laser power, cleaning speed, and pulse repetition frequency—on surface roughness (Sa) and carbon residue rate (RC). Plackett–Burman design was employed to identify significant factors, the method of the steepest ascent was utilized to approximate the optimal region, and a quadratic regression model was constructed using Box–Behnken response surface methodology. The results reveal that the Y-direction cleaning speed and pulsed laser power exert the most pronounced influence on surface roughness (F-values of 112.58 and 34.85, respectively), whereas CW laser power has the strongest effect on the carbon residue rate (F-value of 57.74). The optimized process parameters are as follows: CW laser power set at 625.8 W, pulsed laser power at 250.08 W, Y-direction cleaning speed of 15.00 mm/s, and pulse repetition frequency of 31.54 kHz. Under these conditions, the surface roughness (Sa) is reduced to 0.947 μm, and the carbon residue rate (RC) is lowered to 3.67%, thereby satisfying the service performance requirements for engine pistons. This study offers technical insights into the precise control of the hybrid laser cleaning process and its practical application in engine maintenance and the remanufacturing of end-of-life components. Full article

This study analyzes the impact of geometric variations induced by the manufacturing process on the aerodynamic efficiency of an airfoil used in the design of a 3 kW wind turbine blade. For this purpose, a computational fluid dynamics (CFD) analysis was implemented, and the results were compared with those obtained using QBlade software. After blade fabrication, experimental evaluation was performed using the laser triangulation technique, enabling the reconstruction of the deformed airfoils and their comparison with the original geometry. Additional CFD simulations were carried out on the manufactured airfoil to quantify the loss of aerodynamic efficiency due to geometrical deformations. The results show that the geometric deviations significantly affect the aerodynamic coefficients, generating a decrease in the lift coefficient and an increase in the drag coefficient, which negatively impacts the airfoil aerodynamic efficiency. A 14.9% reduction in the rotor power coefficient was observed with the deformed airfoils compared to the original design. This study emphasizes the importance of quality control in wind turbine blade manufacturing processes and its impact on turbine power performance. In addition, the findings can contribute to the development of design compensation strategies to mitigate the adverse effects of geometric imperfections on the aerodynamic performance of wind turbines. Full article

Although corn germ meal is a rich source of dietary fiber, it contains a relatively low proportion of soluble dietary fiber (SDF) and is frequently contaminated with high levels of zearalenone (ZEN). Solid-state fermentation has the dual effects of modifying dietary fiber (DF) and degrading mycotoxins. This study optimized the solid-state fermentation process of corn germ meal using Bacillus subtilis K6 through response surface methodology (RSM) to enhance SDF yield while efficiently degrading ZEN. Results indicated that fermentation solid-to-liquid ratio and time had greater impacts on SDF yield and ZEN degradation rate than fermentation temperature. The optimal conditions were determined as temperature 36.5 °C, time 65 h, and solid-to-liquid ratio 1:0.82 (w/v). Under these conditions, the ZEN degradation rate reached 96.27 ± 0.53%, while the SDF yield increased from 9.47 ± 0.68% to 20.11 ± 1.87% (optimizing the SDF/DF ratio from 1:7 to 1:3). Scanning electron microscopy (SEM) and confocal laser scanning microscope (CLSM) revealed the structural transformation of dietary fiber from smooth to loose and porous forms. This structural modification resulted in a significant improvement in the physicochemical properties of dietary fiber, with water-holding capacity (WHC), oil-holding capacity (OHC), and water-swelling capacity (WSC) increasing by 34.8%, 16.4%, and 15.2%, respectively. Additionally, the protein and total phenolic contents increased by 23.0% and 82.61%, respectively. This research has achieved efficient detoxification and dietary fiber modification of corn germ meal, significantly enhancing the resource utilization rate of corn by-products and providing technical and theoretical support for industrial production applications. Full article

As manufacturing demands for challenging-to-machine metallic materials continue to evolve, the performance of cutting tools has emerged as a critical limiting factor. The synergistic application of micro-texture and coating in cutting tools can improve various properties. For the processing of existing micro-texture, because of the fast cooling and heating processing method of laser, there are defects such as remelted layer stacking and micro-cracks on the surface after processing. This study introduces a preheating-assisted technology aimed at optimizing the milling performance of textured coated tools. A milling test platform was established to evaluate the performance of these tools on titanium alloys under thermally assisted conditions. The face-centered cubic response surface methodology, as part of the central composite design (CCD) experimental framework, was employed to investigate the interaction effects of micro-texture preparation parameters and thermal assistance temperature on milling performance. The findings indicate a significant correlation between thermal assistance temperature and tool milling performance, suggesting that an appropriately selected thermal assistance temperature can enhance both the milling efficiency of the tool and the surface quality of the titanium alloy. Utilizing the response surface methodology, a multi-objective optimization of the textured coating tool-preparation process was conducted, resulting in the following optimized parameters: laser power of 45 W, scanning speed of 1576 mm/s, the number of scans was 7, micro-texture spacing of 130 μm, micro-texture diameter of 30 μm, and a heat-assisted temperature of 675.15 K. Finally, the experimental platform of optimization results is built, which proves that the optimization results are accurate and reliable, and provides theoretical basis and technical support for the preparation process of textured coating tools. It is of great significance to realize high-precision and high-quality machining of difficult-to-machine materials such as titanium alloy. Full article

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

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 research article examines the CO₂ laser cutting performance of Fused Filament Fabricated Acrylonitrile Styrene Acrylate (ASA) thermoplastics by analyzing the influence of plate thickness, laser power, and cutting speed on four quality characteristics: surface roughness (Ra), top kerf width (Top KW), bottom kerf width (Bottom KW), and bottom heat-affected zone (Bottom HAZ). Forty-five experiments were conducted using five thickness levels, three power levels, and three cutting speeds. To model and predict these outputs, seven machine learning approaches were employed: Autoencoder, Autoencoder–Gated Recurrent Unit, Autoencoder–Long Short-Term Memory, Random Forest, Extreme Gradient Boosting (XGBoost), Support Vector Regression, and Linear Regression. Among them, XGBoost yielded the highest accuracy across all performance metrics. Analysis of Variance results revealed that Ra is mainly affected by plate thickness, Bottom KW by cutting speed, and Bottom HAZ by power, while Top KW is influenced by all three parameters. The study proposes an effective prediction framework using multi-output modeling and hybrid deep learning, offering a data-driven foundation for process optimization. The findings are expected to support intelligent manufacturing systems for real-time quality prediction and adaptive laser post-processing of engineering-grade thermoplastics such as ASA. This integrative approach also enables a deeper understanding of nonlinear dependencies in laser–material interactions. Full article

The unique structures and properties of natural organisms provide abundant inspiration for surface modification research in materials science. In this paper, the tribological advantages of radial ribs found on shell surfaces were combined with laser cladding to address challenges in material surface strengthening. Laser cladding technology was used to fabricate bionic units on the surface of 20CrMnTi steel. The alloy powder consisted of a Ni-based alloy with added WC particles. The influence of laser power (1.0 kW–3.0 kW) on the dimensions, microstructure, hardness, surface roughness, and tribological properties of the bionic units was investigated to enhance the tribological performance of the Ni60/WC bionic unit. The microstructure, phase composition, hardness, and tribological behavior of the bionic units were characterized using scanning electron microscopy (SEM), X-ray diffraction (XRD), a microhardness tester, and a wear tester. Experimental results show that the dimensions of the bionic units increased with laser power. However, beyond a certain threshold, the growth rate of the width and height gradually slowed due to heat conduction and edge cooling effects. The microstructure primarily consisted of equiaxed and dendritic crystals, with grain refinement observed at higher laser powers. The addition of WC resulted in average hardness values of 791 HV_0.2, 819 HV_0.2, 835 HV_0.2, and 848 HV_0.2 across the samples. This enhancement in hardness was attributed to dispersion strengthening and grain refinement. Increasing the laser power also reduced the surface roughness of the bionic units, though excessively high laser power led to a roughness increase. The presence of WC altered the wear mechanism of the bionic units. Compared to the wear observed in the N60 sample, the wear amount of the WC-containing samples decreased by 73.7%, 142.1%, 157.5%, and 263.1%, respectively. Hard WC particles played a decisive role in enhancing tribological performance of the bionic unit. Full article

Fine-grained Yb:Y₂O₃ laser ceramics with excellent transmittance and thermal conductivity were fabricated from commercial powders. The process involved aqueous colloidal forming, additive-free air pre-sintering at 1400 °C, and hot isostatic pressing at 1550 °C. Suspensions were prepared with a deionization process to alleviate the hydrolysis issue, which optimizes the microstructure uniformity and enhances the green compacts’ density after consolidation. The microstructure, in-line transmittance, microhardness, and fracture toughness of the Yb³⁺-doped Y₂O₃ ceramics with different concentrations were measured. The 5.0 at% Yb³⁺-doped Y₂O₃ ceramic yielded a superior transmittance of 80.1% at 1100 nm and 83.0% in the mid-infrared region. The average grain size was 752 nm. The sample exhibited a thermal conductivity of 9.94 W·m⁻¹·K⁻¹ while achieving a 1076 nm laser output with a 42 mW peak power and 4.3% slope efficiency. Full article

In this work, we report the formation of multiple mode-locking states in an Erbium/Ytterbium co-doped fiber laser, such as domain-wall (DW) dark pulses, high-order dark harmonic pulses, dissipative soliton resonance (DSR) pulses, and dual-wavelength h-shaped pulses. By increasing the pump power and adjusting the quarter-wave retarder (QWR) plates, we experimentally achieve 310th-order harmonic dark pulses. DSR pulses emerge at a pump power of 1.01 W and remain stable up to 9.07 W, reaching a maximum pulse width of 676 ns and a pulse energy of 1.608 µJ, while Dual-wavelength h-shaped pulses have a threshold of 1.42 W and maintain stability up to 9.07 W. Using a monochromator, we confirm that these h-shaped pulses result from the superposition of a soliton-like pulse and a DSR-like pulse, emitting at different wavelengths but locked in time. The fundamental repetition rate for dark pulsing, DSR, and h-shaped pulses is 321.34 kHz. This study provides new insights into complex pulse dynamics in fiber lasers and demonstrates the versatile emission regimes achievable through precise pump and polarization control. Full article

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

The functional performance of magnesium hydroxide (Mg(OH)₂) is intrinsically governed by its crystallographic morphology. Herein, we demonstrate an electrochemical deposition strategy to synthesize Mg(OH)₂ from abandoned MgCl₂ resources in salt lakes, achieving simultaneous waste valorization and morphology control. Systematic investigations were conducted on the effects of polyvinylpyrrolidone (PVP) and polyethylene glycol (PEG) as surfactants on electrochemical parameters (cell voltage, pH, current efficiency, and energy consumption) and morphological evolution (XRD, SEM, and laser particle size analysis). Results show that the cell voltage and pH increased proportionally with surfactant concentration, with a current efficiency of 93.86% and an optimal energy consumption of 4.15 kW h·t⁻¹ at an optimal PVP concentration of 6 g·L⁻¹. PEG addition exhibited a similar trend in process parameter modulation. Morphological evolution analysis revealed that appropriate PEG dosage promoted the transformation of irregular Mg(OH)₂ flakes into near-spherical platelets, accompanied by a measurable increase in particle size. This work establishes structure–property relationships between surfactant molecular design and Mg(OH)₂ crystallization, providing theoretical support for the controllable electrochemical preparation of magnesium hydroxide with different morphologies. Furthermore, it opens up a novel and innovative technical pathway to promote the high-value utilization of abandoned magnesium resources in salt lakes. Full article

Laser-Directed Energy Deposition (LDED) has recently been widely used for 3D-printing metal components and repairing high-value parts. One key performance indicator of the LDED process is represented by melt pool stability and spatter behavior. In this research study, an off-axis vision monitoring system is employed to characterize spatter formation based on different anomalies in the process. This study utilizes a 1 kW fiber laser-based LDED system equipped with a monochrome high-dynamic-range (HDR) vision camera and an SP700 Near-IR/UV Block visible bandpass filter positioned at various locations. To extract meaningful features from the original images, a novel image processing algorithm is developed to quantify spatter counts, orientation, area, and distance from the melt pool under harsh conditions. Additionally, this study analyzes the average number of spatters for different laser power settings, revealing a strong positive correlation. Validation experiments confirm over 93% detection accuracy, underscoring the robustness of the image processing pipeline. Furthermore, spatter detection is employed to assess the impact of spatter formation on deposition continuity. This research study provides a method for detecting spatters, correlating them with LDED process parameters, and predicting deposit quality. Full article

This study systematically revealed the synergistic effects of laser power, cladding speed, and substrate diameter on the dilution rate and hardness of iron-based alloy coatings on the surface of 45 steel through the integration of finite element simulation, elemental migration analysis, and response surface methodology (RSM). The experiments showed that when the substrate diameter was greater than 50 mm, the coupling effect of thermal diffusion retardation and molten pool expansion caused a nonlinear surge in the dilution rate. The growth rate of the molten pool depth increased by 46% (from 0.28 to 0.41 μm), and the melting volume of the substrate expanded by 1.7 times. The dilution rate reached 15.6%–31.7% through a dual-regulation mechanism involving energy density (1.43–3.75 J/mm²) and substrate diameter (30–60 mm), with a significant hardness demarcation of 343–738 HV. Substrates with a small diameter (30 mm) achieved a peak hardness of 738 HV at an energy density of 2.14 J/mm² through ultra-fast cooling (>1.5 × 10⁴ K/s), while those with a large diameter (60 mm) exhibited a hardness drop to 426.5 HV due to grain coarsening. The multi-method integrated model constructed in this study achieved a dilution rate prediction error of less than 5% (R² = 0.9775), with a prediction deviation of less than 2% under extreme parameters (diameter of 55 mm and power of 4800 W). The study proposed an optimized process window with a substrate diameter of 42–57 mm and an energy density of 1.43–2.14 J/mm², providing a physically mechanism-driven intelligent parameter design strategy for laser cladding repair of shaft parts. Full article

Microwave Plasma Chemical Vapor Deposition (MPCVD) plays a crucial role in the growth of high-quality diamonds. However, during the MPCVD process, residues such as polycrystalline diamond, and graphite often adhere to the high-temperature growth substrate surfaces, potentially degrading diamond growth quality. To effectively remove these contaminants and improve the quality of diamond growth, this study employed an 800 kHz femtosecond laser to clean growth substrates with residual deposits. We assessed the effects of multiple cleaning cycles on residue removal from the Foundation Trench Region (FTR) and Inwall Region (IR) and on substrate quality. The results indicate that multiple scans at a laser power of 2.38 W, a repetition rate of 800 kHz, a scanning speed of 1800 mm/s, and a scan spacing of 10 μm significantly removed residues, reduced substrate surface roughness, and restored substrate cleanliness. This approach enhances the quality and efficiency of diamond growth via MPCVD. The application of high-repetition-rate femtosecond laser cleaning techniques for growth substrates significantly improves the quality of regenerated diamond films, providing crucial support for the preparation of high-quality diamond materials. Full article