Search Results (94)

High-power 355 nm ultraviolet (UV) lasers, leveraging their short wavelength, high photon energy, and high absorption across a broad range of materials, have become indispensable light sources for precision manufacturing, semiconductor processing, and laser direct imaging (LDI). In this paper, we demonstrate a high-power 355 nm UV laser system based on a narrow-linewidth polarization-maintaining (PM) Yb-doped fiber laser and cascaded frequency conversion. A single-frequency semiconductor laser is employed as the seed source, with its spectral linewidth broadened to 0.32 nm (full width at half maximum, FWHM) via phase modulation to suppress stimulated Brillouin scattering (SBS). Through a PM master oscillator power amplifier (MOPA) architecture, a maximum average output power of 899 W at 1064 nm is achieved with a beam quality factor of M² = 1.12 (M²_x = 1.11, M²_y = 1.13). By employing lithium triborate (LiB₃O₅, LBO) crystals for extracavity cascaded second-harmonic generation (SHG) and sum-frequency generation (SFG), a maximum green output power of 613.7 W at 532 nm is obtained, corresponding to a SHG conversion efficiency of 68.2%, and a maximum UV output power of 227.1 W at 355 nm is achieved, with a total conversion efficiency of 25.2%. At the maximum output power, the UV beam quality factors are M² = 1.16 (M²_x = 1.24 and M²_y = 1.09), and the power fluctuation is better than ±1.5% root-mean-square (RMS) over 8 h of continuous operation. These results indicate that the cascaded frequency conversion approach based on narrow-linewidth PM fiber lasers possesses the capability for further scaling to higher-power single-path high-brightness UV output and can provide high-brightness UV sources for applications such as flexible printed circuit (FPC) laser cutting, flat-panel display laser direct imaging, and semiconductor wafer scribing. Full article

Sapphire, with excellent optical properties and high hardness, has become a key hard and brittle material component in extreme environments like aviation equipment and infrared detection systems. Its processing quality directly determines the performance of various equipment systems. To address processing defects, technologies such as multi-wire cutting, magnetorheological polishing, chemical mechanical polishing, femtosecond laser processing, and ion beam etching have been developed and studied to improve the surface quality of sapphire components. This paper focuses on key technologies, including sapphire’s nano-scale surface morphology control, intrinsic nano-surface atomic-level defect control, and combined process systems for precision and shape control. These technologies lay the foundation for sapphire components’ process chain manufacturing to achieve high-precision shape and surface quality control. Full article

Dynamic beam shaping opens new possibilities for improving the quality and productivity of industrial laser material processing applications such as welding and cutting. However, dynamic beam shaping involves time constants and frequencies that must be selected correctly to successfully modify a given laser process. This paper proposes a standardized nomenclature for the possible types of dynamic beam shaping and the resulting dynamic process modifications, and relates these to characteristic time constants and frequencies at which the process modifications have a particularly strong influence on the process. These characteristic frequencies define three process regimes that have distinctly different effects on the process. An overview of typical time constants and frequencies in laser processes aids in understanding the occurrence of characteristic frequencies. Knowledge of the process regimes allows for a systematic selection of frequencies in dynamic beam shaping to achieve targeted dynamic process modifications, e.g., for pore reduction. Using a laser system capable of dynamic beam shaping at frequencies of up to 80 MHz, the influence of the three process zones on the porosity of the weld was demonstrated using deep welds in cast aluminum as an example. Full article

With the advancement of SiC wafers toward 12 inches and innovations in laser cutting technology, new demands have emerged for SiC grinding techniques—namely, high efficiency, low loss, and low wear ratio. This paper investigates electrochemical-assisted grinding of SiC using a grinding wheel–SiC pair model system, examining the effects of electrolyte type, concentration, voltage, load, and rotational speed on wear behavior. Experimental results reveal that NaCl is the most effective electrolyte among the six candidates tested. In the NaCl system, wear behavior is strongly influenced by the interplay between voltage and rotational speed. At a constant voltage of 3 V, increasing the rotational speed to 600 rpm produces a wear area of 1911.93 μm², while at a higher voltage of 7 V with a lower speed of 200 rpm, the wear area reaches 1301.96 μm², indicating that optimal material removal requires synergistic matching of electrical and mechanical parameters. At 2 wt% NaCl, a sudden change in wear behavior occurs at 6–7 min, indicating a dynamic balance between oxide formation and mechanical removal. Rotational speed shows a turning point at 600 rpm, where the wear mechanism shifts significantly, marking the transition to a synergistically enhanced regime. EDS analysis confirms that Na₂SO₄ increases surface oxygen content by 54.4% compared to deionized water, demonstrating enhanced electrochemical oxidation. The optimal parameter window for synergistic removal is identified as 1–2 wt% NaCl, 5–7 V, 600 rpm, and 100–150 g. This study provides quantitative insights into the synergistic removal mechanism of SiC, offering a theoretical foundation for developing efficient, low-loss electrochemical grinding technologies. Full article

This paper presents a stochastic framework for the inverse identification of structural material degradation (SMD) in cantilever beams. The method combines the Karhunen–Loéve (KL) expansion for the efficient parameterisation of spatially varying material decay with experimental Frequency Response Function (FRF) data within a Bayesian inference scheme. This approach employs a low-dimensional spectral parameterisation via the KL expansion, which mitigates the curse of dimensionality inherent in element-wise model updating, and provides a full-field probabilistic description of SMD. A two-phase constraint strategy was developed to address the fundamental tension between physical plausibility and algorithmic stability of the inverse identification algorithm: (1) physical regularisation during identification stabilises the ill-posed inverse problem, and (2) post-convergence selective regularisation eliminates physically impossible stiffness enhancements (exceeding 1.1 × baseline) that arise from measurement and modelling uncertainties. This phased approach prevents the algorithm distortion that occurs when constraints are applied too stringently during iteration, while ensuring final results respect fundamental physical principles. The framework is experimentally validated on a steel cantilever beam with a symmetric open-edge cut. Laser vibrometry measurements under swept-sine excitation demonstrate successful localisation and quantification of SMD, with the 95% credible interval accurately capturing the damaged region after physical constraint application. The adaptive constraint strategy resolves the delicate balance between mathematical stability and physical plausibility in inverse identification. Full article

This paper presents a breakthrough in activating the skin effect at conventional broaching speeds (1–8 m/min) by using laser defocus gradient modification to induce surface embrittlement in martensitic stainless steel Z10C13. Through controlled defocusing, a 50 μm gradient remelting layer was created, which features ultrafine grains (0.8 μm) and a high-density geometrically necessary dislocation (GND) zone (ρGND = 2.27 μm⁻³). The quasi-cleavage fracture was triggered via dislocation pinning by non-oriented low-angle grain boundaries (28.4% LAGBs). Multiscale characterization confirms that this microstructural transformation enhances surface hardness by 12.95% (reaching 31.4 HRC), reduces cutting force by 34.07%, and improves surface roughness by 63.74% (Sz = 28.80 μm). Simultaneously, a parallel crack-deflection mechanism restricts subsurface damage propagation, resulting in a crack-free subsurface zone. These results demonstrate the effectiveness of the embrittlement–toughening dichotomy for precision machining of difficult-to-cut materials under low-speed constraints. Full article

The purpose of this paper is to examine the application and development of CAD/CAM technologies in the modern metal cutting industry, with a focus on their role in increasing production accuracy, efficiency, and sustainability. The study presents an industrial case of laser cutting of AISI 304 stainless-steel sheets, in which two approaches are compared under identical material and technological parameters: conventional manual nesting and automatic nesting based on algorithms implemented in a CAD/CAM environment. The methodology evaluates both layouts using clear technical and economic indicators, including number of parts per sheet, material utilization, cutting time, weight of scrap, and cost per sheet. For the analyzed batch, automatic nesting increases the number of parts per sheet from 44 to 76 (≈73%), reduces the unused sheet area from 61% to 39%, and shortens the cutting time from 12 to 9 min (≈25%), which leads to a reduction in material waste by about 36% and cost savings of approximately 314 EUR per sheet. As a result, the process becomes more efficient and reliable, supporting sustainable and digital manufacturing goals. The findings confirm the importance of algorithmic optimization in CAD/CAM systems for enhancing industrial competitiveness, enabling effective resource management, and facilitating the transition towards Industry 5.0. Full article

Laser engraving may be used in a variety of industries, from medicine to defense, and it has many uses that require high-quality precision production. However, in practice, operators have to adjust the laser settings manually, which can result in wasted material and poor color quality and even decrease productivity. Current optimization approaches mostly concentrate on single objectives, making it impossible to co-optimize engraving quality and production efficiency simultaneously. In this paper, an approach based on a multi-objective genetic algorithm, a combination of NSGA-II, SPEA2, and MOEA/D, is proposed to automatically establish the relationship between CMYK color attributes, which are extracted from images of engravings, and laser parameters (power, speed, and frequency). Anodized aluminum 6061 was laser-processed using an SPI 30W fiber laser. While the proposed framework is general, the experimental validation in this study was specifically constrained to this material. The results also indicate that MOEA/D converges in a short time and becomes relatively stable after 20 generations. NSGA-II results in solutions that are more diverse, and SPEA2 offers a good trade-off between the speed of convergence and solution size. This approach resulted in optimization in terms of both a decrease in material used and color matching between manual operations, with the average CMYK improvement being up to 28%. Our results indicate that multi-objective evolutionary optimization is feasible for the optimization of efficiency and quality in laser cutting. Full article

Picosecond laser drilling offers high precision and quality, and compared to femtosecond lasers, it also balances processing efficiency, making it widely used across various fields. However, existing drilling processes still face issues such as roundness and taper. Therefore, further research into the processing characteristics of picosecond laser technology is needed to improve processing quality. This paper uses ANSYS software to conduct numerical simulations of picosecond laser ring-cutting drilling, analyzing the temperature field of microholes under ring-cutting scanning paths as parameters change. Experimental studies were conducted using AISI 310S heat-resistant stainless steel as the base material. This material exhibits excellent high-temperature oxidation resistance and strength retention, making it suitable for laser thermal processing. Using a single-factor method, the study investigated the influence of equidistant concentric circular paths and inner-dense-outer-sparse concentric circular paths on microhole morphology characteristics. The results show that the laser energy distribution is different under different paths. The entrance aperture of the equidistant concentric circle path is larger than that of the inner dense and outer sparse concentric circle path, while the exit aperture is smaller than the latter. Moreover, the roundness is also better than that of the inner dense and outer sparse concentric circle path. The taper of the inner dense and outer sparse concentric circle path is better than that of the equidistant concentric circle path. This study can provide a reference for the optimization of different processing paths in the future. Full article

Laser ranging technology holds a key position in the military, aerospace, and industrial fields due to its high precision and non-contact measurement characteristics. As a core component, the performance of the photon detector directly determines the ranging accuracy and range. This paper systematically reviews the technological development of photonic detectors for laser ranging, with a focus on analyzing the working principles and performance differences of traditional photodiodes [PN (P-N junction photodiode), PIN (P-intrinsic-N photodiode), and APD (avalanche photodiode)] (such as the high-frequency response characteristics of PIN and the internal gain mechanism of APD), as well as their applications in short- and medium-range scenarios. Additionally, this paper discusses the unique advantages of special structures such as transmitting junction-type and Schottky-type detectors in applications like ultraviolet light detection. This article focuses on photon counting technology, reviewing the technological evolution of photomultiplier tubes (PMTs), single-photon avalanche diodes (SPADs), and superconducting nanowire single-photon detectors (SNSPDs). PMT achieves single-photon detection based on the external photoelectric effect but is limited by volume and anti-interference capability. SPAD achieves sub-decimeter accuracy in 100 km lidars through Geiger mode avalanche doubling, but it faces challenges in dark counting and temperature control. SNSPD, relying on the characteristics of superconducting materials, achieves a detection efficiency of 95% and a dark count rate of less than 1 cps in the 1550 nm band. It has been successfully applied in cutting-edge fields such as 3000 km satellite ranging (with an accuracy of 8 mm) and has broken through the near-infrared bottleneck. This study compares the differences among various detectors in core indicators such as ranging error and spectral response, and looks forward to the future technical paths aimed at improving the resolution of photon numbers and expanding the full-spectrum detection capabilities. It points out that the new generation of detectors represented by SNSPD, through material and process innovations, is promoting laser ranging to leap towards longer distances, higher precision, and wider spectral bands. It has significant application potential in fields such as space debris monitoring. Full article

Laser cladding, a cutting-edge surface modification technique for metals, offers a novel approach to enhancing the wear and corrosion resistance of substrates due to its rapid heating and cooling capabilities, precise control over coating thickness and dilution rates, and non-contact processing characteristics. However, disparities in the physical properties between the coating material and the substrate, coupled with the improper utilization of process parameters, can lead to coating defects, thereby compromising the quality of the coating. This paper examines the effects of material systems and process parameters on laser cladding composite coatings and shows that cracking is mainly caused by thermal and residual stresses. This article summarizes the methods for crack improvement and prevention in five aspects: the selection of processes in the preparation stage, the application of auxiliary fields in the cladding process, heat treatment technology, the use of auxiliary software, and the search for new processes and new structural materials. Finally, the future development trends of laser cladding technology are presented. Full article

Microfluidic devices are used in numerous scientific fields and research areas, but device fabrication is still a time- and resource-intensive process largely confined to the cleanroom or a similarly well-equipped laboratory. This paper presents a method to create microfluidic devices in under three hours using the silicone polymer polydimethylsiloxane (PDMS) and a laser cut positive master using PDMS double casting without a cleanroom or other large capital equipment. This method can be utilized by an undergraduate student with minimal training in a laboratory with a modest budget. This paper presents “Same Day Microfluidics” as a fabrication method accessible to research groups not currently fabricating their own microfluidic devices and as an option for established research groups to more quickly create prototype devices. The method is described in detail with timing, materials, and technical considerations for each step and demonstrated in the context of a Y-channel coflow device. Full article

The miniaturization of smart materials has become a new trend in the modern manufacturing industry due to its enormous application in the aerospace, biomedical, and automobile sectors. Nickel–titanium (NiTi)-based binary shape memory alloys (SMAs) are one of the smart materials with certain supreme features like shape memory effect, pseudo-elasticity, high ductility, strong corrosion-resistance, and elevated wear resistance. For this, several micro-machining processes have been developed to machine NiTi SMAs. This paper summarizes all of the conventional and non-conventional micro-machining processes employed to machine NiTi SMAs. In this review process, the surface integrity, dimensional accuracy of the machined surface, cutting force and tool wear analysis during conventional and non-conventional micro-machining of NiTi SMA are evaluated mostly with the aid of input process variables like cutting speed, depth of cut, width of cut, types of coolants, tool coating, discharge voltage, capacitance, laser fluence, pulse duration, scan speed, electrolysis concentration and gap voltage. The optimization of process parameters using different methods during conventional and non-conventional micro-machining of NiTi SMAs is also analyzed. The problems faced during conventional micro-machining of NiTi SMAs are overcome by non-conventional micro-machining processes as discussed. The present study aims to recognize potential developments in the improvement of the micro-machinability of NiTi SMAs. Full article

The aim of the research is to investigate the impact of laser operation parameters on the LIG (laser-induced graphene) process. It focuses on evaluating the feasibility of using the induced conductive layers to create antenna circuits that are dedicated to radio-frequency identification (RFID) technology. Given the specific design of textile RFIDtex transponders, applying the LIG technique to fabricate antenna modules on a flexible substrate (e.g., Kapton) opens new possibilities for integrating RFID labels with modern materials and products. The paper analyses the efficiency of energy and data transmission in the proposed innovative UHF RFID_LIG tags. The signal strength, read range, and effectiveness are estimated in the experimental setup, providing key insights into the performance of the devices. Based on the obtained results, it can be concluded that changes in laser cutting parameters, the size of the induced graphene layer, and the method of fixing the Kapton substrate significantly affect the quality of the cutting/engraving components and the conductivity of burned paths. However, these changes do not directly affect the correct operation of the RFID_LIG transponders, owing to the fact that these structures are resistant to external impacts. Nevertheless, an increased range of data readout from the RFID_LIG tags can be achieved by using graphene paths with higher conductivity. The obtained results confirm the validity of the proposed concept and provide a foundation for further research on adapting the LIG method to automated logistics, ultimately leading to the development of more versatile and innovative solutions for identification processes. Full article

Carbon fiber/polyether ether ketone (CF/PEEK) is widely used in aerospace, transportation, and other high-end industries for its light weight, high strength, and recyclability. However, its inherently brittle–ductile two-phase structure presents challenges in processing CF/PEEK. This paper introduces a laser-assisted milling method, wherein four types of CF/PEEK unidirectional plates (0°, 45°, 90°, and 135°) are milled under varying laser powers and spindle speeds. The results are compared with conventional milling (CM) techniques, based on cutting forces, temperatures, surface roughness, and damage defects. The cutting force, temperature, and surface quality were optimal at a fiber direction of 0° and were least favorable at 90° under identical machining conditions. When the fiber direction was 90°, the milling temperatures at 400 W and 500 W laser power decreased by 19.8% and 7.9%, respectively, while the average values of Fx and Fy decreased by 20.5% and 9.55%, compared to conventional milling. Furthermore, the laser-assisted milling method significantly reduces surface defects and improves surface roughness. In CF/PEEK composites, brittle fracture is the primary material removal mechanism, with damage characteristics such as fiber fracture, fiber pullout, and fiber/matrix debonding. The optimal parameter combination is a 0° fiber orientation, 400 W laser power, and a spindle speed of 4000 rpm. This study provides theoretical and technical support for the high-quality processing of CF/PEEK composites. Full article