Search Results (4,511)

A high-sensitivity fiber-optic hot-wire anemometer based on a liquid-filled leaky-guided fiber Mach–Zehnder interferometer (LGFMZI) with UV-cured polymer/aluminum-microparticle photothermal encapsulation is proposed and experimentally demonstrated. The sensing element consists of a side-polished-fiber-assisted liquid-filled hollow-core fiber structure, in which a refractive-index-selected liquid core is introduced through a microslit to tailor the modal effective refractive-index difference and enlarge the free spectral range. The sensing region is uniformly encapsulated with a UV-cured NOA81 polymer layer containing aluminum microparticles. This encapsulation layer serves as both a photothermal conversion layer under 980 nm LD heating and a mechanical reinforcement layer. Under laser heating, the sensor is subsequently cooled by external airflow, converting wind-velocity variations into monotonic wavelength shifts. Experimental results show that, at an LD current of 80 mA corresponding to an optical power of 16 mW, the single-wavelength-dip sensor achieves a maximum airflow sensitivity of −22.922 nm/(m/s). The device also exhibits a fast transient response, with a rise time of 0.606 s and a fall time of 0.316 s. The proposed liquid-filled LGFMZI combines simple fabrication, photothermal encapsulation, high spectral readability, and stable airflow response, making it suitable for real-time fiber-optic hot-wire anemometry. Full article

In this study, laser powder bed fusion (PBF-LB) 022Cr17Ni12Mo2 steel plates with dimensions of 50 mm × 50 mm × 2 mm were fabricated using a laser power of 206 W, a scanning speed of 900 mm/s, a hatch spacing of 90 μm, a layer thickness of 30 μm, and an interlayer scanning rotation of 67°. The specimens were then subjected to solution treatment at 900–1100 °C for 30 min and at 950 °C for 30–120 min. Unlike previous ultrasonic studies on additively manufactured metals, which mainly focused on defect detection, elastic-constant characterization, or residual stress evaluation, this work investigates whether solution-treatment-induced changes in grain size and dislocation density can be quantitatively reflected by laser-ultrasonic attenuation and further correlated with yield strength. Laser ultrasonic nondestructive testing using a 1064 nm pulsed laser with a pulse width of 8 ns and a pulse energy of 500 mJ was combined with metallographic observation, EBSD characterization, XRD analysis, tensile testing, and microhardness measurement. The results show that the solution-treated samples retained a single-phase γ-austenitic structure, while microstructural recovery, weakening of PBF-LB-induced cellular substructures, and partial annihilation of cell-wall dislocations led to a reduction in KAM-derived dislocation density from 2.04 × 10¹⁴ m⁻² to 1.45 × 10¹⁴ m⁻² and a decrease in yield strength from 466.9 MPa to 407.4 MPa. Within the present dataset, the EBSD-equivalent grain size showed an apparent positive correlation with ultrasonic attenuation, while the KAM-derived dislocation density showed an empirical negative correlation with ultrasonic attenuation. However, ultrasonic attenuation should be interpreted as a combined microstructure-sensitive response rather than as a response controlled only by EBSD-equivalent grain size or dislocation density. Based on the empirical correlations among ultrasonic attenuation, EBSD-equivalent grain size, KAM-derived dislocation density, and yield strength, a preliminary attenuation-based calibration model was established for the present solution-treated samples. The model should be regarded as an in-sample empirical calibration within the present experimental range rather than a general Hall–Petch-based predictive model. The model showed good in-sample fitting performance, with (R²) values higher than 0.85 and a maximum in-sample fitting error of 3.85%. However, because the model was established and assessed using the same eight solution-treatment conditions, it should be regarded as a preliminary calibration model within the present experimental range rather than a general predictive model. This study demonstrates the potential of laser ultrasonic attenuation for non-contact evaluation of microstructural and mechanical-property variations in solution-treated PBF-LB 022Cr17Ni12Mo2 steel. Full article

Traditional bone plates provide reliable fracture fixation; however, their high stiffness can cause stress shielding, thereby reducing mechanical stimulation of the bone tissue and slowing its regeneration. The biomechanical performance of a titanium plate with a localized porous structure for osteosynthesis of the radial shaft was investigated in this study. Three designs were considered: a solid plate and two plates with localized porous regions measuring 10 × 10 mm and 10 × 15 mm. The finite element analysis of the bone–plate system was performed using MSC Patran/Nastran, with rigid fixation of the proximal end of the bone and sequential application of an axial compressive load of 100 N, bending, and torsion with a moment of 1 N·m. Biomechanical performance was evaluated based on von Mises equivalent stress, fragment displacement (FD), interfragmentary movement (IFM), interfragmentary strain (IFS), and strain energy density (SED). To confirm the manufacturability of the design, the plate was fabricated from Ti–6Al–4V alloy using laser powder bed fusion (LPBF), and the geometry of the porous structure was verified by scanning electron microscopy. The results showed that the localized porous structure altered the load distribution between the plate and the bone, resulting in an increase in local stresses in the bone under the investigated loading conditions. These changes indicate an alteration in the mechanical environment within the bone, which may potentially affect conditions related to fracture healing. Among the investigated configurations, the plate with a 10 × 10 mm porous insert demonstrated the most balanced mechanical characteristics in terms of stresses in the implant, stress distribution in the bone, and structural stability. Full article

Non-mechanical beam steering technology based on liquid crystal optical switches and liquid crystal polarization gratings holds significant application prospects in fields such as laser communication, radar detection, and optical information processing. Traditional nematic liquid crystal optical switches exhibit slow response speeds, whereas novel ferroelectric liquid crystal optical switches, despite their fast response, are hampered in engineering applications by complex fabrication processes, the large number of devices required for cascading, and substantial module thickness. To address these issues, this paper proposes and demonstrates a fast non-mechanical beam steering scheme by cascading a stressed polymer network liquid crystal (SPNLC) optical switch with a liquid crystal polarization grating. The SPNLC is fabricated by mechanically shearing a polymerized liquid crystal–polymer composite, enabling sub-millisecond response and continuous linear phase modulation without the need for an alignment layer. A 30-μm-thick SPNLC half-wave plate was prepared, which introduces a phase retardation of 3.6 μm under a driving voltage of 300 V, and the rise time and fall time are measured to be approximately 526 μs and 560 μs at a driving voltage of 20 V with a 1 kHz square wave, and 470 μs and 538 μs at 27 V under the same waveform conditions. Cascaded with a passive polarization grating, the waveplate enables fast electrical switching of the beam between the ±1st diffraction orders. Furthermore, a two-dimensional multi-angle beam deflector was constructed based on a supra-binary cascade scheme. Experimental results confirm that the system possesses sub-millisecond response, large phase retardation, continuous tunability, and an alignment-layer-free fabrication process, demonstrating its feasibility for large-range fast beam scanning. Full article

This paper comprehensively investigates the ultraviolet (UV) nanosecond laser fabrication of micro-groove textures on planar PEEK surfaces, as well as their surface performance in terms of wettability and frictional properties. Firstly, a three-dimensional finite element model, incorporating a moving Gaussian heat source, solid heat transfer and deformed geometry, was established to simulate the transient temperature field and ablation profile of PEEK during UV laser ablation. The predicted groove depth agreed with the experimental value with a low deviation of 11.19%. Based on the simulation and single-factor experiments, the optimized single-track laser parameters were determined as a laser power of 1.2 W, a scanning speed of 100 mm/s and a repetitive frequency of 100 kHz. Secondly, systematic single-factor and multi-pass laser ablation experiments of PEEK surfaces were conducted to fabricate micro-groove textures with precisely tailored geometric parameters. Furthermore, ablated surface characterization showed that the laser-textured surfaces exhibited increased roughness, apparent crystallinity up to 22.13%, and pronounced anisotropic wettability, with improved liquid spreading along the groove direction and restricted spreading across the grooves. Finally, fretting wear tests under simulated body fluid lubrication were carried out. The research findings reported in this paper provide a systematic theoretical and experimental basis for the application of UV nanosecond laser surface texturing in the fabrication of PEEK-based components. Full article

Current micro/nanosystems mainly rely on a planar fabrication framework, where structures are built layer-by-layer on flat surfaces. This conventional approach leaves vertical sidewalls underutilized, posing geometric limits in packaging density, three-dimensional (3D) interconnects, and multi-surface functionalization. To overcome these constraints, sidewall patterning has emerged as a promising strategy, enabling 3D integrated circuits, templates for directed nanostructure synthesis, and microfluidic drag reduction. Nevertheless, traditional photolithography and non-photolithographic techniques face challenges when applied to vertical or curved 3D surfaces. Unidirectional radiation and restricted focal depths prevent high-fidelity pattern transfer, even when using soft lithography, scanning probes, or nanoimprinting. To address these geometric and mechanical barriers, our group has developed several approaches for patterning the sidewalls of microsystems, which are the primary focus of this review. Building upon our approaches, this review further surveys related sidewall-patterning strategies, including micro-transfer printing, multi-stimuli-responsive mechanics, block copolymer self-assembly, two-photon polymerization, and laser-induced forward transfer. Collectively, these techniques expand the capabilities of sidewall engineering and provide valuable insights into next-generation 3D micro- and nanomanufacturing. Full article

High-port-count fiber pump combiners are important passive components for scalable laser diode (LD) power combining in high-power fiber-laser systems. However, increasing the number of input ports from 19 to 37 narrows the fabrication window because fiber bundle packing, taper uniformity, splice matching, thermal management, and backward-light tolerance must be controlled simultaneously. In this work, a 37 × 1 tapered fiber bundle pump combiner was fabricated by a tubing-based method using thirty-seven 135/155 µm multimode input fibers and an 800/880 µm output fiber. The input fibers were weakly etched to improve bundle compactness, and the glass-tube-assisted fiber bundle was tapered, cleaved, and fusion-spliced with a tapered output fiber. The fabricated combiner was characterized using thirty-seven 915 nm fiber-coupled LDs. At a total injected power of 4.89 kW, the combiner delivered 4.80 kW output power, corresponding to an overall transmission efficiency of 98.16%. The single-port transmission efficiencies were approximately in the range of 97.3–98.1%, indicating good port-to-port uniformity for the dense 37-fiber bundle. During full-power operation, the highest temperature appeared in the tapered fiber bundle region and reached 103.8 °C, while the fusion-splice region reached 76.2 °C. In addition, the device withstood 500 W backward-propagating light without observable damage, indicating its practical tolerance to reverse-power loading. These results show that the proposed 37 × 1 fiber pump combiner provides an effective all-fiber solution for multi-kilowatt LD power combining. Full article

Background: Micro-reservoirs in implant surfaces represent a promising drug carrier concept for drug delivery systems. For drug loading, inkjet printing enables highly precise droplet positioning. However, droplet drying influences drug crystallization from printed drug solution. This study investigates how evaporation-driven phenomena affect the precision and homogeneity of inkjet-based deposition of a crystallizing drug into exemplary micro-reservoirs. The aim is to guide the selection of suitable solvents and inkjet process parameters. Methods: Laser-drilled micro-reservoirs were fabricated as blind holes with entrance diameters of 100 µm and 400 µm in the surface of specimens of EN 1.4404 (equivalent to AISI 316L) stainless steel, a commonly used biomaterial. The reservoirs were loaded with two different drug solutions using piezoelectric drop-on-demand inkjet printing. Acetylsalicylic acid (ASA) was applied as a model drug representing crystallizing small-molecule drugs. Solvents with markedly different evaporation rates, ethanol (EtOH) as a representative high-volatility solvent and dimethyl sulfoxide (DMSO) as a representative low-volatility solvent, were selected. The number of jetted droplets per dispensing step was varied. Precision and homogeneity of the drug deposition were investigated using light and laser scanning microscopy. Results: Over the course of droplet drying, two phenomena, the coffee-ring effect and creeping, can impair drug deposition quality. The coffee-ring effect leads to inhomogeneous, ring-shaped drug deposits. Creeping is the evaporation-driven spreading of crystalline structures and reduces the precision of drug deposition. The EtOH-based ASA solution (c = 10 g/L) was intensely affected by both phenomena. Inhomogeneities could be partially compensated via tailoring the droplet count per dispensing step. The DMSO-based solution (c = 100 g/L) exhibited a more compact crystallization of ASA (requiring ~20% less volume in an exemplary experiment), no coffee-ring effect, and only minor creeping. Conclusions: The DMSO-based ASA solution enabled a more precise and homogeneous drug deposition than the EtOH-based solution under the investigated printing and crystallization conditions. EtOH-related limitations could be counteracted by controlling the number of jetted droplets per dispensing step. Full article

This study presents a systematic investigation into the mechanical responses of two tungsten-based alloys—84W–11.2Ni–4.8Fe and 88W–8.4Ni–3.6Fe—fabricated via selective laser melting (SLM). Quasi-static compression tests using a universal testing machine and dynamic impact experiments employing a split Hopkinson pressure bar (SHPB) were conducted over a temperature range of 298–598 K and strain rates spanning from 1 × 10⁻³ s⁻¹ to 2.3 × 10³ s⁻¹. Both alloys exhibited significant strain-rate hardening and thermal softening effects. Based on the experimental data, a Johnson–Cook (J–C) constitutive model was established. The fidelity of the calibrated model for the 84W alloy was rigorously validated through pulsed X-ray radiography and static armor penetration tests. The SLM-fabricated 84W-shaped charge liner produced a well-collimated jet with a tip velocity of 5101.5 m/s and achieved a penetration depth of 87 mm into rolled homogeneous armor (RHA)-equivalent steel targets. Numerical simulations using the developed J–C model showed close agreement with experimental measurements, with a maximum discrepancy of only 9.19%, thereby confirming the predictive capability of the constitutive model. These results demonstrate that the proposed J–C model can reliably characterize the large-deformation behavior of SLM-processed 84W and 88W liners under the extreme thermomechanical conditions characteristic of shaped charge jet formation—namely high temperature, high pressure, and ultra-high strain rate. Collectively, this work establishes a foundational framework for the application of SLM technology to shaped charge liner design and provides a critical basis for further research into jet formation physics and penetration mechanics of tungsten-based alloys. Full article

To address the challenges of weak NO₃⁻ adsorption, insufficient active hydrogen supply, and facile desorption of NO₂⁻ intermediates in neutral electrocatalytic nitrate reduction reaction (NO₃RR), this study employs laser nano-welding technology to fabricate a Ru/WO₃ heterojunction, and constructs a Ru/WO₃/Cu(OH)₂/FC spatially confined electrode using Cu(OH)₂ nanorod arrays as the support. Laser welding achieves metallurgical-grade bonding between Ru and WO₃ while retaining oxygen vacancies in WO₃. Cu(OH)₂ promotes NO₃⁻ adsorption via electrostatic and Lewis acid interactions, and its nanorod array structure confines NO₂⁻ intermediates. In 0.5 M K₂SO₄ + 50 mM KNO₃ electrolyte, the electrode delivers an ammonia yield rate of 16.1 mg h⁻¹ cm⁻² and a Faradaic efficiency of 75.8% at −0.8 V vs. RHE, outperforming control groups. Potential-dependent electrochemical impedance spectroscopy (EIS) confirms that spatial confinement suppresses NO₂⁻ accumulation and optimizes interfacial charge transfer kinetics, providing a new strategy for electrode design in neutral NO₃RR. Full article

Titanium alloys are widely used for implants, yet corrosion, bacterial colonization and incomplete osseointegration remain important causes of interfacial failure. This review critically analyzes major biomedical functional coating fabrication techniques employed to enhance the surface properties of titanium alloys, including micro-arc oxidation, anodic oxidation, magnetron sputtering, electrochemical deposition, electrophoretic deposition, plasma spraying, physical vapor deposition, plasma immersion ion implantation, laser surface treatment, and hybrid (composite) approaches. For each method, key operational principles, structural and functional characteristics, performance advantages and limitations, and representative application domains are critically analyzed. Across these routes, biological performance depends on coating continuity, pore or nanotube geometry, interfacial bonding, phase composition and ion release. Calcium- and phosphorus-rich oxides and hydroxyapatite deposits generally promote cell adhesion, proliferation, alkaline phosphatase activity, mineralization and osteogenic differentiation. Dense oxide, nitride, tantalum and carbon-based films strengthen corrosion barriers, whereas Mn, Zn, Cu and Ag containing surfaces can inhibit bacterial adhesion and biofilm formation. Excessive ion release, however, may compromise cytocompatibility. Reported outcomes also vary with test medium, exposure time, bacterial strain and cell model. Standardized quantitative endpoints and longer-term corrosion, biofilm and osseointegration studies are required to guide clinically reliable multifunctional coatings. Full article

The dissimilar combination of NiTi shape memory alloy and Ti6Al4V titanium alloy offers superelasticity, biocompatibility and high specific strength, showing broad application prospects in aerospace and medical fields. However, when fabricating NiTi/Ti6Al4V composite components by multi-material laser powder bed fusion (MM-LPBF), brittle cracks or even complete delamination easily occur at the interface. In this paper, without relying on intermediate interlayer materials, we innovatively propose a root-inspired three-dimensional bio-interlocking interface structure. By means of macroscopic three-dimensional geometric interlocking, the crack propagation path and load transfer mode are forced to change. Using the branching angle (45°, 60°) and the structural size multiplier (1.2, 1.5) as variables, the influence of the bio-inspired geometric parameters on the interfacial forming quality, microstructure and mechanical properties was systematically investigated. The results show that the branching angle is the primary factor determining the performance. The 45° low-angle branched specimens exhibit overall brittle delamination along the flat metallurgical reaction interface under shear loading, with an average shear strength of only 17.47 MPa. In contrast, the 60° high-angle branched specimens, owing to their larger normal embedding depth, exhibit a failure mode transitioning to a mixed mode that includes crack deflection, branch shearing and plastic tearing of the Ti6Al4V matrix. Although TEM confirms that a continuous Ti₂Ni brittle phase still exists at the interface, the optimised 60–1.5 structure increases the average shear strength to 128.37 MPa, which is more than six times higher than that of the 45–1.2 group (17.47 MPa). This “geometrical constraint toughening” strategy provides a new paradigm for the interfacial strengthening of dissimilar metals without relying on metallurgical modification. Full article

Surface icing poses a significant risk to unmanned aerial vehicles (UAVs) and compact aerospace platforms, where limited onboard power and space require efficient anti-/de-icing surfaces. In this study, micro/nanostructures were fabricated on TC4 titanium alloy (Ti–6Al–4V) surfaces by femtosecond laser processing at different scanning speeds. The effects of scanning speed on surface morphology, wettability, static freezing, dynamic droplet behavior, and electrothermal de-icing performance were systematically investigated. Increasing the scanning speed induced nonlinear changes in microstructure height and surface roughness, while variations in ablation intensity caused nonuniform material redistribution. The surface processed at 250 mm/s showed the best anti-icing performance, with a water contact angle of 157.5 ± 0.5° and a maximum freezing delay 21.5 times longer than untreated TC4. During electrothermal de-icing, melting initiated at discrete ice–substrate contact points, forming coalesced meltwater films, while interfacial stress concentration promoted crack propagation and rapid ice detachment. Compared with untreated surfaces, ice detachment time (250 mm/s) achieved complete ice detachment at approximately 152 s, whereas ice on the untreated surface remained adhered after 270 s of continuous heating, representing a de-icing time reduction of at least 44%. These results demonstrate that combining laser-fabricated microstructures with electrothermal heating effectively reduces real ice–substrate contact, providing an enhanced anti-/de-icing strategy for lightweight, long-endurance UAV applications under identical electrical input. Full article

Selective laser melting (SLM) and electron beam melting (EBM) enable the fabrication of commercially pure titanium, but the effects of the fabrication method and build orientation on surface characteristics and bonding remain unclear. This study evaluated the surface roughness, wettability, and shear bond strength of titanium fabricated by SLM and EBM at build orientations of 0°, 45°, and 90°, with titanium ingots intended for dental casting serving as reference specimens. The surfaces were wet-ground, air-abraded with 50 µm alumina particles, and treated with a 10-methacryloyloxydecyl dihydrogen phosphate-containing metal primer. Surface roughness (Sa), static water contact angles before and after primer application, and shear bond strength to a resin luting agent after 24 h of water storage were evaluated (n = 15/group). The EBM specimens fabricated at 90° exhibited significantly greater Sa values than the other groups (p < 0.05). Primer application significantly increased the water contact angle in all groups (p < 0.05), although group-dependent differences were observed. No significant differences in shear bond strength were detected among the fabrication conditions (p > 0.05). Thus, under the tested surface treatment conditions, differences in surface roughness and wettability were not accompanied by corresponding differences in the initial bond strength of commercially pure titanium. Full article

Porous Ti-6Al-4V lattice implants combine high specific strength, osseointegrative porosity, and compatibility with additive manufacturing, but conventional stiffness tuning through porosity, pore size, or unit-cell topology compromises biological pore requirements. This study presents a computational design framework in which structural kurtosis, the normalized interlayer offset between neighboring layers of a periodic cubic lattice, regulates elastic response at fixed global porosity. Closed-form expressions for the effective modulus are derived from first principles: the aligned configuration from the axial load-bearing area fraction, and the interlayer-shifted configuration from Euler–Bernoulli beam theory for guided-end connecting members. The derivations reproduce the Gibson–Ashby exponents n = 1 and n = 2, replacing the previously asserted power law, and a calibrated one-parameter interpolation bridges intermediate offsets. At 65% porosity, the effective modulus falls from 16.5 GPa in the aligned lattice to 2.64 GPa in the shifted lattice. A local-yield analysis based on peak bending curvature gives recoverable elastic strains of 1.37% at 89% porosity and 0.68% at 65%; the compliance-based values of 20.5% and 5.12% are kinematic upper bounds that neglect plastic hinging. A prefactor-free benchmark shows that obtaining the same 6.25-fold reduction by increased porosity alone would require 85.9–94.4% porosity and 0.17–0.28 mm struts, outside the osseointegration window and the resolution of selective laser melting. A GAN-CAD-FEA workflow reproduced the analytical moduli to within 7% across six design cases. All results are analytical and numerical; no specimens were fabricated or tested, and experimental validation remains required. Full article