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Metals
Special Issues
Progress in Laser Advanced Manufacturing
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Progress in Laser Advanced Manufacturing

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Additive Manufacturing".

Deadline for manuscript submissions: 31 May 2024 | Viewed by 7175

Special Issue Editors

Prof. Dr. Gang Yu

E-Mail Website
Guest Editor
Institute of Mechanics, Chinese Academy of Sciences, Beijing 100190, China
Interests: laser advanced manufacturing; interaction of laser materials processing; experimental characterization; numerical simulation; data-driven modeling; artificial intelligence
Dr. Zhiyong Li

E-Mail Website
Guest Editor
Institute of Mechanics, Chinese Academy of Sciences, Beijing 100190, China
Interests: additive manufacturing; laser welding; multi-scale, multi-physics simulation; data-driven modeling; artificial intelligence

Special Issue Information

Dear Colleagues,

In modern industry communities, laser advanced manufacturing has been increasingly widely applied in the automotive, aerospace, energy, and chemical industries—to name a few—since its invention in 1960; this increase is a result of its advantages in manufacturing, including flexible transmission, easier automatic control and spatial-temporal transformation, and high accuracy. Amidst their rapid development, manufacturing technologies in which laser beams are used as the main tool could be classified into three groups, according to the mass variation of substrate materials, as follows: material-addition technology, such as laser additive manufacturing and laser welding; material-removal technology, including laser drilling and laser cutting; and mass conservation technology, e.g., laser surface modification and laser-assisted bending.

Typically, laser advanced manufacturing of metals is a process characterized with multi-temporal, multi-spatial, multi-physics strong coupling. Taking metal laser welding as an example, the energy distribution from the high-power density laser beam, the temperature field, the velocity field, the concentration field of the melt pool, the thermal stress, and the deformation are directly coupled, resulting in different joint performances. The interaction between laser photons and atoms of materials occurs on a microscale, the formation of the melt pool together with heat and mass transfer occurs on a mesoscale, and thermal deformation occurs on a macroscale. The multi-scale coupling and cross-scale effect are key features for metal manufacturing using laser beams.

As a result of the extreme manufacturing conditions—e.g., high temperature, high cooling rate, and rapid solidification—the further promotion of laser manufacturing remains restricted by major challenges. For example, defects including hot cracking, pores, and micro-segregation occur in laser additive manufacturing; spattering and cracking occur in high-efficiency, high-quality, defect-free laser welding of aluminum and copper in the electric and automotive industries; and the control of hole morphology is difficult in high-precision laser micro-drilling of metals. Scientific studies must work to solve these challenges and promote the development of laser advanced manufacturing.

This Special Issue is thus organized to publish state-of-the-art works which aim to explore new ideas, new points, and new conclusions surrounding these challenges in laser advanced manufacturing. Manuscripts focused on insightful experimental devices or strategies, novel numerical modeling methods, and promising data-driven models assisted by artificial intelligence are especially welcomed for submission to this Special Issue.

Prof. Dr. Gang Yu
Dr. Zhiyong Li
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • additive manufacturing
  • laser welding
  • laser drilling
  • laser cutting
  • laser-assisted bending
  • laser surface modification
  • numerical simulation
  • data-driven modeling
  • experimental characterization
  • artificial intelligence

Published Papers (4 papers)

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Research

14 pages, 5698 KiB  
Article
Morphological Characteristics and Printing Mechanisms of Grid Lines by Laser-Induced Forward Transfer
by Yanmei Zhang, Chongxin Tian, Yucui Yu, Xiuli He, Yanhua Bian, Shaoxia Li and Gang Yu
Metals 2022, 12(12), 2090; https://doi.org/10.3390/met12122090 - 6 Dec 2022
Cited by 1 | Viewed by 1117
Abstract
Laser-induced forward transfer (LIFT) is an innovative metallization technique used in the processing of grid lines of solar cells for the photovoltaics industry. A study on the morphology and transfer mechanisms of formed lines with high-viscosity silver paste and small gap was performed [...] Read more.
Laser-induced forward transfer (LIFT) is an innovative metallization technique used in the processing of grid lines of solar cells for the photovoltaics industry. A study on the morphology and transfer mechanisms of formed lines with high-viscosity silver paste and small gap was performed in this paper. There were three different transfer states under different laser fluences: non-transferred lines or transferred but no continuous lines, continuous transferred lines, and explosive transferred lines. There was a critical transfer threshold for the continuous line transfer under different processing speeds. Higher processing speed required a larger critical transfer threshold. The line width increased as the laser fluence increased. For all continuous formed lines, the cross-sectional morphologies with single and double peaks were shown at critical and above transfer threshold, respectively. Two symmetrical protrusions with steep edges were observed for the formed line with double peaks. By comparing the silver paste remaining on the donor and transferred to the acceptor under different laser fluences, it can be found the transferred silver paste exhibited a retracting characteristic under the critical and above transfer threshold. While a stretching characteristic was obvious when the laser fluence was much higher than the transfer threshold. Morphological characteristics with single or double peaks were determined by the distance between the rupture position of the bridge and the bottom of the bubble, under the action of the axial combined forces. This work can provide insights for improving fine-line metallization and understanding transfer mechanisms in the photovoltaic application and flexible electronics devices. Full article
(This article belongs to the Special Issue Progress in Laser Advanced Manufacturing)
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10 pages, 3154 KiB  
Article
Study of Tensile Strength of Aluminum Alloy Caused by Pulsed Laser Drilling
by Heyan Gao, Ying Wang, Jifei Ye, Lan Li, Bangdeng Du, Sai Li and Mingyu Li
Metals 2022, 12(12), 2049; https://doi.org/10.3390/met12122049 - 29 Nov 2022
Cited by 5 | Viewed by 1191
Abstract
In the process of pulsed laser drilling, the material properties in the heat-affected zone will change due to the thermal effect of the laser. To study the effect of this change on the material tensile strength, two lasers were used to punch the [...] Read more.
In the process of pulsed laser drilling, the material properties in the heat-affected zone will change due to the thermal effect of the laser. To study the effect of this change on the material tensile strength, two lasers were used to punch the standard 6061 aluminum alloy specimens with millisecond and nanosecond pulse widths, and then the tensile test was carried out on the standard specimens with a tensile tester to measure the ultimate tensile strength of the aluminum alloy. Finally, the micro-morphology of the fracture was photographed by scanning electron microscopy (SEM), and the fracture mechanism of the aluminum alloy was analyzed. The experimental results show that the relationship between the rate of intensity change induced by the millisecond laser and the ablation area ratio is more linear than that of the nanosecond laser; with the increase of ablation area ratio, the rate of intensity changes induced by the nanosecond and millisecond lasers becomes increasingly closer; three types of fractures are produced with two types of laser ablation; the plasticity of the material rapidly decreases with laser drilling, and the main reason for decrease in plasticity was stress concentration. This study provides an important point of reference for how to ensure the strength and plasticity of the components after laser drilling. Full article
(This article belongs to the Special Issue Progress in Laser Advanced Manufacturing)
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18 pages, 5279 KiB  
Article
Surface Tension-Driven Flow and Its Correlation with Mass Transfer during L-DED of Co-Based Powders
by Zhiyong Li, Gang Yu, Xiuli He, Shaoxia Li and Zhuang Shu
Metals 2022, 12(5), 842; https://doi.org/10.3390/met12050842 - 14 May 2022
Cited by 6 | Viewed by 1997
Abstract
Laser direct energy deposition (L-DED) is one of the most promising additive manufacturing methods, which has been paid more and more attention in recent years. An improved heat and mass transfer model was developed here to analyze thermal behavior, driving force, surface tension-driven [...] Read more.
Laser direct energy deposition (L-DED) is one of the most promising additive manufacturing methods, which has been paid more and more attention in recent years. An improved heat and mass transfer model was developed here to analyze thermal behavior, driving force, surface tension-driven flow and its correlation with dilution during L-DED of Co-based powders to a 38MnVS substrate. Thermal behavior was firstly studied for its fundamental influence on fluid flow and mass transfer. Next, the roles of capillary force and thermal capillary force were characterized using both the dimensional analysis and simulation methods, and the mechanism of surface tension-driven flow was also qualitatively investigated. Finally, flow characteristics inside the melt pool were studied in detail and their correlation with the dilution phenomenon was analyzed based on the multi-component mass transfer model. The temperature gradient was found to be much larger at the front of the melt pool, and it took about 200 ms for the melt pool to reach a quasi-steady condition. Moreover, sharp changes in the curvature of the solid/liquid boundary were observed. Surface tension was demonstrated as the main driver for fluid flow and resulted in centrally outward Marangoni flow. Capillary force contributes to the reduction of the curvature of the free surface, and thermal capillary force (Marangoni force) dominated the Marangoni convection. Alloy elements from the powders, such as Co and Ni, were added to the front part of the melt pool and mainly diluted at the upper side of the rear region near the symmetric plane of the melt pool. Fundamental results in this work provide a valuable understanding of the surface tension-driven flow and its correlation with concentration dilution during the additive manufacturing process. Full article
(This article belongs to the Special Issue Progress in Laser Advanced Manufacturing)
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22 pages, 13948 KiB  
Article
Effect of Surface-Active Element Oxygen on Heat and Mass Transfer in Laser Welding of Dissimilar Metals: Numerical and Experimental Study
by Binxin Dong, Zhiyong Li, Gang Yu, Shaoxia Li, Chongxin Tian, Yanhua Bian, Zhuang Shu and Xiuli He
Metals 2022, 12(4), 556; https://doi.org/10.3390/met12040556 - 25 Mar 2022
Cited by 1 | Viewed by 2143
Abstract
The effects of the surface-active element oxygen on the laser welding of 304 stainless steel (304SS) and nickel were numerically and experimentally studied in pure argon and argon–oxygen mixed gas atmospheres containing 21% oxygen (AMO). In this study, the molten pool morphology, thermal [...] Read more.
The effects of the surface-active element oxygen on the laser welding of 304 stainless steel (304SS) and nickel were numerically and experimentally studied in pure argon and argon–oxygen mixed gas atmospheres containing 21% oxygen (AMO). In this study, the molten pool morphology, thermal behavior, solidification phenomenon, correlation between dilution and convection flow, and microhardness of welding joints were analyzed. As a result of oxygen effects, the molten pool was deeper, the maximum temperature was higher, and the maximum flow velocity was lower in the AMO. The cooling rate (GR) and combination parameter (G/R) were studied by the direct simulation of temperature gradient (G) and solidification growth rate (R). Combined with the solidification microstructure, it was found that oxygen had little effect on grain size. The major elements Fe, Cr, and Ni within the solidified molten pool in the AMO were uniformly diluted, while the distribution of the above elements was non-homogenous in pure argon. Stronger flow and multiple directions of convection inside the molten pool contributed to uniform dilution in the AMO. The distribution of microhardness was similar to the content of Cr, and the microhardness at the substrate interface of the joint was higher in the AMO than in pure argon. The preliminary conclusions of this study provide in-depth insights into the effects of surface-active element oxygen on heat and mass transfer in laser dissimilar welding. Full article
(This article belongs to the Special Issue Progress in Laser Advanced Manufacturing)
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