Search Results (96)

Combined pulse laser systems combining continuous-wave (CW) lasers and nanosecond pulsed lasers have shown clear advantages in metal ablation and surface modification. However, the plasma shielding effect induced by nanosecond pulses and the associated shock-wave phenomena in hybrid laser systems remain insufficiently investigated, particularly regarding their influence on CW laser energy coupling. In this study, the ablation behavior of metal targets under the combined irradiation of a 500 W CW laser and nanosecond pulsed lasers with pulse energies ranging from 0.4 J to 1.0 J was investigated. High-speed plasma imaging was employed to analyze laser–material interaction characteristics, including absorption behavior and molten material ejection, while high-speed infrared thermography was used to monitor transient temperature evolution during combined pulse laser processing. Macroscopic and microscopic analyses were conducted to characterize damage morphology, and a three-dimensional surface profilometer was used to quantitatively evaluate ablation efficiency. The results show that, under combined pulse laser irradiation, the removed volume increased from 0.05 mm³ to 0.618 mm³ and the ablation depth increased from 0.136 mm to 0.776 mm. Compared with CW laser processing alone, the ablation efficiency was markedly enhanced. This improvement is attributed to the combined effects of optimized energy deposition, thermal distribution, and material response. In addition, the plasma shielding effect was observed to vary with nanosecond pulse energy, indicating that precise energy control is critical for performance enhancement. This study demonstrates the potential of combined pulse laser technology for high-efficiency and high-precision metal surface processing and micro–nano fabrication. Full article

To evaluate the influence of different surface conditioning protocols—sandblasting (SB), tribochemical silica coating (TBC), CO₂ laser irradiation, and plasma-enhanced chemical vapor deposition (PECVD-Si coating for 49 min) on surface roughness (Ra), surface morphology, and composite-to-zirconia shear bond strength (SBS). Eighty 3Y-TZP plates were randomly allocated into four groups (n = 20) based on surface conditioning protocol: Group 1 (SB), Group 2 (CO₂ laser), Group 3 (TBC), and Group 4 (PECVD-Si coating for 49 min). From each group, five specimens underwent Ra assessment using a contact profilometer, and five specimens were examined for surface morphology via scanning electron microscopy (SEM). The remaining ten specimens received resin composite buildup, followed by artificial aging. Subsequently, SBS testing was performed using a universal testing machine, and failure modes were evaluated under a stereomicroscope. Statistical analysis was conducted using one-way ANOVA with post hoc Tukey test and chi-square for fracture assessment(α = 0.05). Group 1 (SB) demonstrated the lowest Ra (0.844 ± 0.063 µm) and SBS (12.21 ± 4.6 MPa), whereas Group 4 (PECVD-Si coating for 49 min) exhibited the highest Ra (1.388 ± 0.098 µm) and SBS (30.48 ± 2.5 MPa). Intergroup comparison revealed no statistically significant differences between Groups 2 and 3 for both Ra and SBS values (p > 0.05). However, Groups 1 and 4 differed significantly in both parameters (p < 0.05). PECVD-based silica coating for 49 min demonstrated superior surface conditioning efficacy for 3Y-TZP, yielding significantly higher Ra and SBS values compared to sandblasting, tribochemical silica coating, and CO₂ laser irradiation. Full article

To reduce the friction coefficient and wear in tillage machinery during operation, biomimetic textures with different densities inspired by the short-tailed shrew’s claw were designed using biomimetic principles. These textures were applied to the surface of 65Mn steel using laser processing technology. This study investigated the effects of these bionic textures on the tribological properties of 65Mn steel surfaces in two environments: dry friction and soil friction. Friction and wear tests were conducted, and the friction coefficient, wear morphology, and wear quality were measured using a friction and wear testing machine, a scanning electron microscope (SEM), and a three-dimensional profilometer. The results indicate that under dry friction conditions, the tribological properties of specimens with bionic textures were significantly improved compared to non-textured specimens. The frictional properties of the specimens with bionic textures were optimized at a texture density of 20%, with an average coefficient of friction reduction of 24%. Under soil friction conditions, the samples with bionic textures demonstrated better tribological performance at densities of 20% and 30% compared to the non-textured samples, with decreases in the average coefficient of friction of 1.3% and 2.9%. The special surface structure of the bionic short-tailed shrew claw can effectively reduce friction heat effects and wear, demonstrating significant anti-friction and anti-wear performance. Full article

To evaluate the impact of different surface treatment regimens, Neodymium-doped yttrium orthovanadate (Nd: YVO4) laser, Toluidine blue (TB) activated Low-level laser therapy (LLLT), and Bioactive glass particles (BAGPs) on the surface roughness (Ra), surface morphology, and bond strength (BS) of Glass fiber posts (GFP) bonded to canal dentin. Forty single human rooted incisors with a closed apex were included. The endodontic treatment was performed, followed by post space preparation. Fifty-six GFP were sorted into four categories based on the conditioning method used (n = 14). Group 1: H₂O₂, Group 2: Nd: YVO4 laser, Group 3: TB-LLLT, and Group 4: BAGPs. Surface Ra and topographic changes were identified using a profilometer and Scanning Electron Microscopy (SEM). Post cementation was executed by utilizing self-adhesive resin cement. Analysis of BS and fracture pattern was performed using a universal testing machine and a stereomicroscope, respectively. Variance analysis with Tukey’s test was used to compare Ra and BS between the study groups at different root sections (p < 0.05). Group 2 (Nd: YVO4 laser) displayed the highest Ra scores (1051.54 ± 0.087 µm) and BS at all thirds. Whereas Group 3 TB-activated LLLT exhibited the lowest outcomes of Ra (539.39 ± 0.091) and BS at all three sections. Comparison among the investigated groups displayed that Group 1 (H₂O₂) and Group 2 Nd: YVO₄ exhibited comparable outcomes of Ra and BS (p ˃ 0.05). Nd: YVO₄ laser has the potential to roughen the surface of GFP, thereby enhancing its BS to resin cement Full article

Understanding rock behavior under cutting tools is critical for enhancing cutting processes and forecasting rock behavior in engineering contexts. This study examines the link between mechanical properties and indentation crater morphology of six rocks using a conical indenter until initial fracture. Through indentation testing, mechanical properties (indentation stiffness index k and hardness index HI) were assessed, and crater morphology was analyzed using a 3D laser profilometer. The rocks were categorized into three groups based on specific energy: Class I (slate, shale), Class II (sandstone, marble), and Class III (granite, gneiss). The morphological features of their indentation craters were analyzed both quantitatively and qualitatively. The linear model was used to establish the relationship between crater morphology indices and mechanical properties, with model parameters determined by linear regression. Key findings include: (1) Fracture depth, cross-sectional area, and contour roundness are independent morphological indicators, serving as characteristic parameters for crater morphology, with qualitative and quantitative analyses showing consistency; (2) Post-classification linear fitting revealed statistically significant morphological prediction models, though patterns varied across rock categories due to inherent properties like structure and grain homogeneity; (3) Classification by specific energy revealed distinct mechanical and morphological differences, with significant linear relationships established for all three indicators in Classes II and III, but only roundness showing significance in Class I (non-significant for cross-sectional area and depth). However, all significant models exhibited limited explanatory power (R² = 0.220–0.635), likely due to constrained sample sizes. Future studies should expand sample sizes to refine these findings. Full article

This study looks at the effect of surface conditioners hydrofluoric acid (HFA), Ytterbium fibre laser (YFL), and Hydroxyapatite nanoparticles (HANPs) on the surface roughness (Ra) and shear bond strength (SBS) of different viscosity resin cements to lithium disilicate glass ceramic (LDC). A total of 78 IPS Emax discs were prepared and categorized into groups based on conditioning methods. Group 1 HFA–Silane (S), Group 2: YFL-S, and Group 3: HANPs-S. A scanning electron microscope (n = 1) and profilometer (n = 5) were used on each conditioned group for the assessment of surface topography and Ra. A total of 20 LDC discs for each conditioned group were subsequently categorized into two subgroups based on the application of high- and low-viscosity dual-cured resin cement. SBS and failure mode were assessed. ANOVA and post hoc Tukey tests were employed to identify significant differences in Ra and SBS among different groups. LDC conditioned with HFA-S, HANPs-S, and YFL-S demonstrated comparable Ra scores (p > 0.05). Also, irrespective of the type of conditioning regime, the use of low-viscosity cement improves bond values when bonded to the LDC. LDC treated with YFL-S and HANPs-S can serve as an effective substitute for HFA-S in enhancing the Ra and surface characteristics of LDC. The low-viscosity resin cement demonstrated superior performance by achieving greater bond strength. Full article

The aim was to investigate the impact of laser parameters on the surface morphology of ablated graphene and elucidate the interaction mechanism between carbon materials and femtosecond lasers. A pulsed laser with a wavelength of 1030 nm is employed to infer the ablation threshold of the surface and interface of graphene coatings formed through ultrasonic spraying. The ablation threshold of the coating–substrate interface is verified by numerical simulation. Incorporating the data of groove width and depth obtained from a three-dimensional profilometer and finite element simulation, an in-depth analysis of the threshold conditions of laser ablation in coating materials is accomplished. The results indicate that when the femtosecond laser frequency is 10 kHz, the pulse width is 290 fs, and the energy density reaches 0.057 J/cm², the graphene material can be effectively removed. When the energy density is elevated to 2.167 J/cm², a complete ablation of a graphite coating with a thickness of 1.5 μm can be achieved. The findings of this study validate the evolution law and linear relationship of ablation crater morphology, offering new references for microstructure design and the selection of controllable laser processing parameters. Full article

The main function of triangulation-based laser profile sensors—also referred to as laser profilometers or profilers—is the three-dimensional scanning of moving objects using laser triangulation. In addition to capturing 3D data, these profilometers simultaneously generate grayscale images of the scanned objects. However, the quality of these images is often degraded due to interference of the laser light, manifesting as speckle noise. In profilometer images, this noise typically appears as vertical stripes. Unlike the column fixed pattern noise commonly observed in TDI CMOS cameras, the positions of these stripes are not stationary. Consequently, conventional algorithms for removing fixed pattern noise yield unsatisfactory results when applied to profilometer images. In this article, we propose an effective method for suppressing speckle noise in profilometer images of flat surfaces, based on local column median vectors. The method was evaluated across a variety of surface types and compared against existing approaches using several metrics, including the standard deviation of the column mean vector (SDCMV), frequency spectrum analysis, and standard image quality assessment measures. Our results demonstrate a substantial improvement in reducing column speckle noise: the SDCMV value achieved with our method is 2.5 to 5 times lower than that obtained using global column median values, and the root mean square (RMS) of the frequency spectrum in the noise-relevant region is reduced by nearly an order of magnitude. General image quality metrics also indicate moderate enhancement: peak signal-to-noise ratio (PSNR) increased by 2.12 dB, and the structural similarity index (SSIM) improved from 0.929 to 0.953. The primary limitation of the proposed method is its applicability only to flat surfaces. Nonetheless, we successfully implemented it in an optical inspection system for the furniture industry, where the post-processed image quality was sufficient to detect surface defects as small as 0.1 mm. Full article

Additive manufacturing (AM, also known as 3D printing) is a bottom–up process where variations in process conditions can significantly influence the quality and performance of the printed parts. Digital twin (DT) technology can measure process parameters and printed part characteristics in real-time, achieving online monitoring, analysis, and optimization of the AM process. Existing DT research on AM focuses on simulating the printing process and lacks real-time defect detection and twinning of actual printed objects, which hinders the timely detection and correction of defects. This study developed a DT system for fused deposition modeling (FDM) AM technology that not only accurately simulates the printing process but also performs real-time quality monitoring of the printed parts. A laser profilometer and industrial camera were integrated into the printer to detect and collect real-time morphological data on the printed object. The custom-developed DT software could convert the morphological data of the printed parts into a DT model. By comparing the DT model of the printed object with its three-dimensional model, defect detection of the printed parts was achieved, where the quality of the printed parts was evaluated using a defect percentage index. This study combines DT and AM to achieve process quality monitoring, demonstrating the potential of DT technology in reducing printing defects and improving the quality of printed parts. Full article

Heat-performance nickel-based superalloys are commonly applied in various critical industries. In this work, test samples in the form of turbine blades were manufactured by means of laser powder bed fusion (LPBF) 3D technology. This research focused on comparison of the influences of various surface finishing methods. The mechanical surface post-processing of the LPBF-manufactured Inconel 718 alloy samples consisted of ultrasonic impact treatment (UIT), ultrasonic shot peening (USP), shot peening (SP), and barrel finishing (BF). The surface microrelief was evaluated using a high-precision laser profilometer, while the microstructural features were studied by light optical microscopy (LOM), scanning/transmission electron microscopy (SEM/TEM), and X-ray diffraction (XRD). Potentiodynamic polarization tests were also conducted to compare the surface finishing methods in terms of corrosion resistance improvement of the LPBF-manufactured 718 alloy samples. The effects of the surface microstructure and hardening intensity in combination with residual stresses and surface relief coupled with roughness profile shapes on the room temperature corrosion behavior of plastically deformed 718 alloy specimens manufactured by LPBF were studied. The corrosion rate (CR) of the LPBF-manufactured samples was reduced after post-processing: BF (~16 μm/year), USP (~15 μm/year), SP (~6.5 μm/year), and UIT (~5.5 μm/year). The experimental trends also agreed well with the theoretical trends of uniform corrosion of the studied alloy. Full article

This paper focuses on comparing the three microscopic measurement techniques, confocal, focus variation, and point for focus, for the evaluation of entire fracture surface topographies. The measurements were performed using a Sensofar S Neox 3D optical profilometer and the Mitutoyo QV Apex 302 vision measuring system. The test specimens required for measuring were printed through laser powder bed fusion (LPBF) technology using two materials: Stainless Steel 316L and Inconel 718. The printing was performed with a printing power of 200 W, scanning speed of 800 mm/s, and layer thickness of 30 µm or 50 µm. The measurement differences were analyzed on the basis of void volume (Vv), fractal dimension (Df), and texture isotropy parameters, as well as a general view of the surface topography. The obtained results did not show a comprehensible difference between the applied measurement techniques for particular specimens. Thus, both measurement devices and three measurement techniques can be used to precisely measure the dimensions of LPBF-processed specimens with the entire fracture surface method. Full article

Wet etching is the mainstream fabrication method for single-bar quantum cascade lasers (QCLs). Different etching solutions result in varying etching effects on III-V semiconductor materials. In this study, an efficient and nearly ideal etching solution ratio was proposed for simultaneously etching both InP and GaInAs/AlInAs, and the surface chemical reactions induced by each component of the etching solution during the process were investigated. Using univariate and single-component experiments, coupled with various characterization techniques such as atomic force microscopy (AFM), stylus profilometer, X-ray photoelectron spectroscopy (XPS), and scanning electron microscopy (SEM), we found that the ratio of HBr to hydrogen peroxide significantly determines the etching rate, while the ratio of HCl to hydrogen peroxide affects the interface roughness. The aim of this study was to provide a comprehensive understanding of the effects of different etching solution components, thereby enhancing the understanding of the wet etching process for InP/GaInAs/AlInAs materials. These findings offer valuable insights into efficient QCL fabrication processes and contribute to the advancement of the field. Full article

Radar sensors are critical for obstacle detection and navigation, especially for automated driving. Using the use-case “printing of heating coils on the inside of the front housing (primary radome)” needed for de-icing in winter, it is demonstrated that additive manufacturing (AM) can provide economic and functional benefits for manufacturing of the sensors. AM will allow significant cost reduction by eliminating parts and simplifying the manufacturing process. Different AM technologies for the coils were investigated, first, by applying the conductive traces by fused deposition modeling (FDM), and, second, by printing copper particle-free inks and pastes. The metal layers were electrically and mechanically characterized using a profilometer to measure the trace dimension and a four-point probe to measure the resistance. It was revealed that low-cost conductive filaments with low resistivity and current carrying capacity are commercially still not available. The best option sourced was a copper–polyester-based filament with 6000 µΩcm after printing. Therefore, low-cost particle-free copper inks and commercial copper flake paste were selected to print the heating coil. The Cu particle-free inks were amine-based Cu (II) formate complexes, where the Cu exists in an ionic form. Using contactless printing processes such as ink-jet printing or pneumatic dispensing, the traces could be deposited onto the low-melting temperature (225 °C) polymeric radome structure. After printing, the material needed to be sintered to form the conductive copper traces. To avoid damaging the polymer radome during sintering, two different processes were investigated: low-temperature (<150 °C) sintering in an oven for 30 min or fast laser sintering. The sintered Cu layers achieved the following specific electric resistivities when slowly sintered in the oven: paste 4 µΩcm and ink 8.8 µΩcm. Using laser sintering, the ink achieved 3.2 µΩcm because the locally high temperature provides better sintering. Also, the adhesion was significantly increased to (5 B). Therefore, laser sintering is the preferred technology. In addition, it allows fast processing directly after printing. Commercial equipment is available where printing and laser sintering is integrated. The potential of low-cost copper material and the integration in additive manufacturing of electronic systems using radar sensors as an example are demonstrated in this paper. Full article

Calcium carbonate scaling causes significant damage and financial losses to various industries, particularly in deep-water oil exploration. It is affected by factors like pressure, temperature, pH, solution chemistry, and surface finish. Surface finish is critical, as it interacts with the fluid and serves as a substrate for the anchoring of calcium carbonate crystals. However, many studies investigate this phenomenon under conditions that differ from those encountered in deep-water oil exploration. Tests are commonly performed under atmospheric pressure and lacking fluid flow or CO₂ influence, which limits their relevance to industrial conditions. This study aims to evaluate the influence of surface finish on the formation of calcium carbonate scaling under conditions that more closely resemble actual operating environments. 304 stainless steel was selected to replicate industrial conditions, owing to its chemical stability and common use in industrial settings. The tests were conducted in a plant with high-pressure capabilities, operating under continuous flow conditions with CO₂ injection. Controlled surfaces were prepared through metallographic polishing, machining, sandblasting, and laser texturing techniques. Surface characterization was performed using a 3D optical profilometer and scratch testing to measure the average adhesion force. The polymorphs formed were characterized by Raman spectroscopy. Fractal dimension analysis was applied to quantify the complexity of the analyzed surfaces. The results indicate that surfaces with higher fractal dimensions exhibit greater scaling mass and higher adhesion force. The main polymorph observed was calcite. Additionally, it was noted that the texture orientation relative to the flow affects scaling, with higher scaling values observed on surfaces oriented perpendicular to the flow. These findings are crucial for optimizing material selection and surface treatments in deep-water oil exploration, enhancing operational efficiency and reducing costs. Full article

The quality of surface morphology can reflect the electrical performance of silver-based contacts. Existing research on the correlation of morphological–electrical performance is based solely on empirical models from traditional visual inspections and only considers the impact of visually observable macro-textural features on electrical performance. However, the influence of micro-textural features on electrical performance should not be overlooked. This paper establishes a contactless surface morphology acquisition device based on a laser profilometer to address the assembly characteristics of contact components. Various original profile signals such as surface roughness, waviness, and surface form error are calculated using wavelet transformation, and a robust weight function is introduced to separate micro-textural features from macro-textural features. After the morphological parameters affecting electrical performance are quantified, the variation laws of single and composite morphological parameters on electrical performance are clarified. Parameter optimization iterations and parameter space distribution optimization are performed using a decision tree, and the optimized predictive model forecasts specific electrical parameter values. The predicted results are quantitatively evaluated, establishing evaluation metrics that reflect the errors and degree of fit between the model predictions and actual values from different perspectives. From the experimental results, the accuracy of the predictive model established in this study exceeds 97%. Full article