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Laser Processing and Multi-Energy Field Manufacturing of High-Performance Materials

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (31 August 2023) | Viewed by 15835

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Dr. Xiaoxiao Chen

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Guest Editor

Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo 315201, China
Interests: laser polishing; laser milling; laser processing; digital manufacturing; beam modulation; multi-energy field manufacturing; hybrid machining; five-axis machining; surface quality
Special Issues, Collections and Topics in MDPI journals

Dr. Yaou Zhang

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Guest Editor

School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Interests: electric discharge machining; special processing technology; multi-energy field manufacturing; digital manufacturing; smart manufacturing; movement control of electromechanical systems and special robots
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Dr. Anhai Li

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Guest Editor

School of Mechanical Engineering, Shandong University, Jinan 250061, China
Interests: high-efficiency and precision machining; cutting tools; machined surface integrity; muti-scale and multi-physics modelling; cutting simulation
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The laser is a major invention of the 20th century, along with atomic energy, the computer and semiconductors. Laser processing technology is non-contact, which is suitable for the processing and manufacturing of various materials without cutting forces. During the machining process, the macro-/microprocessing of the mechanical motion and high-speed scanning of galvanometers can be realized. Compared with traditional processing, it has significant advantages in some aspects.

Today, with the development of materials science and technology, various new materials are emerging in an endless stream. People's technical demand for material applications is constantly increasing, and advanced materials have been widely used in various fields. At the same time, composite processing technology is also gradually developing. The composite manufacturing of multiple energy fields can benefit from the advantages of various single energies. After the optimization of various energy field combinations, the high-performance processing of materials can be achieved.

This Special Issue will summarize recent advances in the fields of laser processing and multi-energy field composite manufacturing. Articles published in this Special Issue will cover a variety of topics including, but not limited to, laser processing, special processing technology, high speed cutting, digital manufacturing, beam modulation, multi-energy field manufacturing, hybrid machining, five-axis machining, and surface quality. This Special Issue aims to showcase the latest achievements in the fields of laser processing and multi-energy field composite manufacturing, solicit the most important discoveries, highlight the challenges of processing mechanisms, theories and technologies, and provide an outlook on future directions.

Dr. Xiaoxiao Chen
Dr. Ya'ou Zhang
Dr. Anhai 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. Materials is an international peer-reviewed open access semimonthly 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

laser processing
special processing technology
high-speed cutting
digital manufacturing
beam modulation
multi-energy field manufacturing
hybrid machining
five-axis machining
high-performance materials
surface quality

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Laser and Multi-Energy Field Processing of High-Performance Materials in Materials (3 articles)

Published Papers (11 papers)

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Editorial

Jump to: Research

5 pages, 185 KiB

Open AccessEditorial

Laser Processing and Multi-Energy Field Manufacturing of High-Performance Materials

by Xiaoxiao Chen, Yaou Zhang and Anhai Li

Materials 2023, 16(17), 5991; https://doi.org/10.3390/ma16175991 - 31 Aug 2023

Viewed by 801

Abstract

The laser is one of the major inventions of the 20th century, along with atomic energy, the computer and semiconductors [...] Full article

(This article belongs to the Special Issue Laser Processing and Multi-Energy Field Manufacturing of High-Performance Materials)

Research

Jump to: Editorial

18 pages, 28914 KiB

Open AccessArticle

Investigation on the Coaxial-Annulus-Argon-Assisted Water-Jet-Guided Laser Machining of Hard-to-Process Materials

by Yuan Li, Shuiwang Wang, Ye Ding, Bai Cheng, Wanda Xie and Lijun Yang

Materials 2023, 16(16), 5569; https://doi.org/10.3390/ma16165569 - 10 Aug 2023

Cited by 2 | Viewed by 1029

Abstract

In this study, the novel coaxial-annulus-argon-assisted (CAAA) atmosphere is proposed to enhance the machining capacity of the water-jet-guided laser (WJGL) when dealing with hard-to-process materials, including ceramic matrix composites (CMCs) and chemical-vapor-deposition (CVD) diamond. A theoretical model was developed to describe the two-phase flow of argon and the water jet. Simulations and experiments were conducted to analyze the influence of argon pressure on the working length of the WJGL beam, drainage circle size, and extreme scribing depth on ceramic matrix composite (CMC) substrates. A comparative experiment involving coaxial annulus and helical atmospheres revealed that the coaxial annulus atmosphere disrupts the water jet proactively, while effectively maintaining the core velocity within the confined working length and enhancing the processing capability of the WJGL beam. Single-point percussion drilling experiments were performed on a CMC substrate to evaluate the impact of machining parameters on hole morphology. The maximum depth-to-width ratio of the groove and depth-to-diameter ratio of the hole reached up to 41.2 and 40.7, respectively. The thorough holes produced by the CAAAWJGL demonstrate superior roundness and minimal thermal damage, such as fiber drawing and delamination. The average tensile strength and fatigue life of the CMCs specimens obtained through CAAAWJGL machining reached 212.6 MPa and 89,463.8 s, exhibiting higher machining efficiency and better mechanical properties compared to femtosecond (194.2 MPa; 72,680.2 s) and picosecond laser (198.6 MPa; 80,451.4 s) machining. Moreover, groove arrays with a depth-to-width ratio of 11.5, good perpendicularity, and minimal defects on a CVD diamond were fabricated to highlight the feasibility of the proposed machining technology. Full article

(This article belongs to the Special Issue Laser Processing and Multi-Energy Field Manufacturing of High-Performance Materials)

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16 pages, 11790 KiB

Open AccessArticle

Investigating the Microscopic Mechanism of Ultrasonic-Vibration-Assisted-Pressing of WC-Co Powder by Simulation

by Yuhang Chen, Yun Wang, Lirong Huang, Binbin Su and Youwen Yang

Materials 2023, 16(14), 5199; https://doi.org/10.3390/ma16145199 - 24 Jul 2023

Cited by 2 | Viewed by 1002

Abstract

The ultrasonic-vibration-assisted pressing process can improve the fluidity and the uneven distribution of density and particle size of WC-Co powder. However, the microscopic mechanism of ultrasonic vibration on the powder remains unclear. In this paper, WC particles with diameter 5 μm and Co particles with diameter 1.2 μm were simulated by three-dimensional spherical models with the aid of the Python secondary development. At the same time, the forming process of the powder at the mesoscale is simulated by virtue of the finite element analysis software ABAQUS. In the simulation process, the vibration amplitude was set to 1, 2, and 3 μm. Their influence on the fluidity, the filling density, and the stress distribution of WC-Co powder when the ultrasonic vibration was applied to the conventional pressing process was investigated. The simulation results show that the ultrasonic vibration amplitude has a great influence on the density of the compact. With an increase in the ultrasonic amplitude, the compact density also increases gradually, and the residual stress in the billet decreases after the compaction. From the experimental results, the size distribution of the billet is more uniform, the elastic after-effect is reduced, the dimensional instability is improved, and the density curves obtained by experimentation and simulation are within a reasonable error range. Full article

(This article belongs to the Special Issue Laser Processing and Multi-Energy Field Manufacturing of High-Performance Materials)

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27 pages, 11627 KiB

Open AccessArticle

Effect of Laser Beam Profile on Thermal Transfer, Fluid Flow and Solidification Parameters during Laser-Based Directed Energy Deposition of Inconel 718

by Bo Chen, Yanhua Bian, Zhiyong Li, Binxin Dong, Shaoxia Li, Chongxin Tian, Xiuli He and Gang Yu

Materials 2023, 16(12), 4221; https://doi.org/10.3390/ma16124221 - 7 Jun 2023

Cited by 7 | Viewed by 1447

Abstract

The profile of the laser beam plays a significant role in determining the heat input on the deposition surface, further affecting the molten pool dynamics during laser-based directed energy deposition. The evolution of molten pool under two types of laser beam, super-Gaussian beam (SGB) and Gaussian beam (GB), was simulated using a three-dimensional numerical model. Two basic physical processes, the laser–powder interaction and the molten pool dynamics, were considered in the model. The deposition surface of the molten pool was calculated using the Arbitrary Lagrangian Eulerian moving mesh approach. Several dimensionless numbers were used to explain the underlying physical phenomena under different laser beams. Moreover, the solidification parameters were calculated using the thermal history at the solidification front. It is found that the peak temperature and liquid velocity in the molten pool under the SGB case were lower compared with those for the GB case. Dimensionless numbers analysis indicated that the fluid flow played a more pronounced role in heat transfer compared to conduction, especially in the GB case. The cooling rate was higher for the SGB case, indicating that the grain size could be finer compared with that for the GB case. Finally, the reliability of the numerical simulation was verified by comparing the computed and experimental clad geometry. The work provides a theoretical basis for understanding the thermal behavior and solidification characteristics under different laser input profile during directed energy deposition. Full article

(This article belongs to the Special Issue Laser Processing and Multi-Energy Field Manufacturing of High-Performance Materials)

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15 pages, 9205 KiB

Open AccessArticle

Effect of Ultrasonic Vibration on Microstructure and Fluidity of Aluminum Alloy

by An Li, Zhiming Wang and Zhiping Sun

Materials 2023, 16(11), 4110; https://doi.org/10.3390/ma16114110 - 31 May 2023

Cited by 2 | Viewed by 1084

Abstract

The effect of ultrasonic vibration on the fluidity and microstructure of cast aluminum alloys (AlSi9 and AlSi18 alloys) with different solidification characteristics was investigated. The results show that ultrasonic vibration can affect the fluidity of alloys in both solidification and hydrodynamics aspects. For AlSi18 alloy without dendrite growing solidification characteristics, the microstructure is almost not influenced by ultrasonic vibration, and the influence of ultrasonic vibration on its fluidity is mainly in hydrodynamics aspects. That is, appropriate ultrasonic vibration can improve fluidity by reducing the flow resistance of the melt, but when the vibration intensity is high enough to induce turbulence in the melt, the turbulence will increase the flow resistance greatly and decrease fluidity. However, for AlSi9 alloy, which obviously has dendrite growing solidification characteristics, ultrasonic vibration can influence solidification by breaking the growing α (Al) dendrite, consequently refining the solidification microstructure. Ultrasonic vibration could then improve the fluidity of AlSi9 alloy not only from the hydrodynamics aspect but also by breaking the dendrite network in the mushy zone to decrease flow resistance. Full article

(This article belongs to the Special Issue Laser Processing and Multi-Energy Field Manufacturing of High-Performance Materials)

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16 pages, 5130 KiB

Open AccessArticle

Research on Electrostatic Field-Induced Discharge Energy in Conventional Micro EDM

by Yaou Zhang, Qiang Gao, Xiangjun Yang, Qian Zheng and Wansheng Zhao

Materials 2023, 16(11), 3963; https://doi.org/10.3390/ma16113963 - 25 May 2023

Cited by 1 | Viewed by 981

Abstract

The electrostatic field-induced electrolyte jet (E-Jet) electric discharge machining (EDM) is a newly developed micro machining method. However, the strong coupling of the electrolyte jet liquid electrode and the electrostatic induced energy prohibited it from utilization in conventional EDM process. In this study, the method with two discharge devices connecting in serials is proposed to decouple pulse energy from the E-Jet EDM process. By automatic breakdown between the E-Jet tip and the auxiliary electrode in the first device, the pulsed discharge between the solid electrode and the solid workpiece in the second device can be generated. With this method, the induced charges on the E-Jet tip can indirectly regulate the discharge between the solid electrodes, giving a new pulse discharge energy generation method for traditional micro EDM. The pulsed variation of current and voltage generated during the discharge process in conventional EDM process verified the feasibility of this decoupling approach. The influence of the distance between the jet tip and the electrode, as well as the gap between the solid electrode and the work-piece, on the pulsed energy, demonstrates that the gap servo control method is applicable. Experiments with single points and grooves indicate the machining ability of this new energy generation method. Full article

(This article belongs to the Special Issue Laser Processing and Multi-Energy Field Manufacturing of High-Performance Materials)

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14 pages, 3609 KiB

Open AccessArticle

Prediction of Primary Dendrite Arm Spacing of the Inconel 718 Deposition Layer by Laser Cladding Based on a Multi-Scale Simulation

by Zhibo Jin, Xiangwei Kong, Liang Ma, Jun Dong and Xiaoting Li

Materials 2023, 16(9), 3479; https://doi.org/10.3390/ma16093479 - 29 Apr 2023

Cited by 3 | Viewed by 1591

Abstract

Primary dendrite arm spacing (PDAS) is a crucial microstructural feature in nickel-based superalloys produced by laser cladding. In order to investigate the effects of process parameters on PDAS, a multi-scale model that integrates a 3D transient heat and mass transfer model with a quantitative phase-field model was proposed to simulate the dendritic growth behavior in the molten pool for laser cladding Inconel 718. The values of temperature gradient (G) and solidification rate (R) at the S/L interface of the molten pool under different process conditions were obtained by multi-scale simulation and used as input for the quantitative phase field model. The influence of process parameters on microstructure morphology in the deposition layer was analyzed. The result shows that the dendrite morphology is in good agreement with the experimental result under varying laser power (P) and scanning velocity (V). PDAS was found to be more sensitive to changes in laser scanning velocity, and as the scanning velocity decreased from 12 mm/s to 4 mm/s, the PDAS increased by 197% when the laser power was 1500 W. Furthermore, smaller PDAS can be achieved by combining higher scanning velocity with lower laser power. Full article

(This article belongs to the Special Issue Laser Processing and Multi-Energy Field Manufacturing of High-Performance Materials)

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13 pages, 16091 KiB

Open AccessArticle

Effect of Cr on Microstructure and Properties of WVTaTiCr_x Refractory High-Entropy Alloy Laser Cladding

by Zhaomin Xu, Zhiping Sun, Cheng Li and Zhiming Wang

Materials 2023, 16(8), 3060; https://doi.org/10.3390/ma16083060 - 13 Apr 2023

Cited by 3 | Viewed by 1385

Abstract

WVTaTiCr_x (x = 0, 0.25, 0.5, 0.75, 1) refractory high-entropy alloy coatings were prepared on a 42-CrMo steel plate using laser cladding. The purpose of this work is to investigate the effect of the Cr content on the microstructure and properties of the WVTaTiCr_x coating. The morphologies and phase compositions of five coatings with different Cr contents were comparatively observed. In addition, the hardness and high-temperature oxidation resistance of the coatings were also analyzed. As a result, with the increase in Cr, the coating grains were more refined. All the coating is mainly composed of the BCC solid-solution phase, which promotes the precipitation of the Laves phase with the increase in Cr. The addition of Cr greatly improves the hardness, high-temperature oxidation resistance and corrosion resistance of the coating. The WVTaTiCr (Cr₁) exhibited superior mechanical properties, especially in terms of its exceptional hardness, high-temperature oxidation resistance and outstanding corrosion resistance. The average hardness of the WVTaTiCr alloy coating reaches 627.36 HV. After 50 h of high-temperature oxidation, the oxide weight of WVTaTiCr increases by 5.12 mg/cm², and the oxidation rate is 0.1 mg/(cm²·h). In 3.5 wt% NaCl solution, the corrosion potential of WVTaTiCr is −0.3198 V, and the corrosion rate is 0.161 mm/a. Full article

(This article belongs to the Special Issue Laser Processing and Multi-Energy Field Manufacturing of High-Performance Materials)

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10 pages, 6108 KiB

Open AccessArticle

Experimental Study on Carbon Fiber-Reinforced Composites Cutting with Nanosecond Laser

by Jihao Xu, Chenghu Jing, Junke Jiao, Shengyuan Sun, Liyuan Sheng, Yuanming Zhang, Hongbo Xia and Kun Zeng

Materials 2022, 15(19), 6686; https://doi.org/10.3390/ma15196686 - 27 Sep 2022

Cited by 8 | Viewed by 2030

Abstract

The carbon fiber-reinforced composite (CFRP) has the properties of a high specific strength, low density and excellent corrosion resistance; it has been widely used in aerospace and automobile lightweight manufacturing as an important material. To improve the CFRP cutting quality in the manufacturing process, a nanosecond laser with a wavelength of 532 nm was applied to cut holes with a 2-mm-thick CFRP plate by using laser rotational cutting technology. The influence of different parameters on the heat-affected zone, the cutting surface roughness and the hole taper was explored, and the cutting process parameters were optimized. With the optimized cutting parameters, the minimum value of the heat-affected zone, the cutting surface roughness and the hole taper can be obtained, which are 71.7 μm, 2.68 μm and 0.64°, respectively. Full article

(This article belongs to the Special Issue Laser Processing and Multi-Energy Field Manufacturing of High-Performance Materials)

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17 pages, 13313 KiB

Open AccessArticle

Study on the Grooved Morphology of CMC-SiC_f/SiC by Dual-Beam Coupling Nanosecond Laser

by Tao Chen, Xiaoxiao Chen, Xuanhua Zhang, Huihui Zhang, Wenwu Zhang and Ganhua Liu

Materials 2022, 15(19), 6630; https://doi.org/10.3390/ma15196630 - 24 Sep 2022

Cited by 3 | Viewed by 1719

Abstract

Due to the excellent properties of high hardness, oxidation resistance, and high-temperature resistance, silicon carbide fiber reinforced silicon carbide ceramic matrix composite (CMC-SiC_f/SiC) is a typical difficult-to-process material. In this paper, according to the relationship between the spatial posture of dual beams and the direction of the machining path, two kinds of scanning methods were set up. The CMC-SiC_f/SiC grooving experiments were carried out along different feeding directions (transverse scanning and longitudinal scanning) by using a novel dual-beam coupling nanosecond laser, and the characteristics of grooving morphology were observed by Laser Confocal Microscope, Scanning Electron Microscopy (SEM), and Energy Dispersive Spectrometer (EDS). The results show that the transverse scanning grooving section morphology is V shape, and the longitudinal scanning groove section morphology is W shape. The grooving surface depth and width of transverse scanning are larger and smaller than that of longitudinal scanning when the laser parameters are the same. The depth of the transverse grooving is greater than that of the longitudinal grooving when the laser beam is transverse and longitudinal scanning, the maximum grooving depth is approximately 145.39 μm when the laser energy density is 76.73 J/cm², and the minimum grooving depth is approximately 83.76 μm when the laser energy density is about 29.59 J/cm². The thermal conductivity of fiber has a significant effect on the local characteristics of the grooved morphology when using a medium energy density grooving. The obvious recasting layer is produced after the laser is applied to CMC-SiC_f/SiC when using a high energy density laser grooving, which directly affects the grooved morphology. Full article

(This article belongs to the Special Issue Laser Processing and Multi-Energy Field Manufacturing of High-Performance Materials)

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17 pages, 14211 KiB

Open AccessArticle

Surface Properties of Medium-Entropy Alloy Coatings Prepared through a Combined Process of Laser Cladding and Ultrasonic Burnishing

by Xuehui Shen, Chang Liu, Baolin Wang, Yu Zhang, Guosheng Su and Anhai Li

Materials 2022, 15(16), 5576; https://doi.org/10.3390/ma15165576 - 13 Aug 2022

Cited by 2 | Viewed by 1470

Abstract

The preparation of functional coatings on metal substrates is an effective method to enhance the surface of steel structures with good serviceability in applications for engineering parts. The objective of this research is to analyze the surface properties of two sorts of medium-entropy alloy (MEA) coatings prepared by laser cladding. After cladding, the two prepared coatings were strengthened by ultrasonic burnishing (UB) treatment. Cladding coating samples before and after being UB-treated were comparatively tested in order to investigate the process effects of UB. When compared with corresponding untreated coating samples, the roughness values of the two sorts of UB-treated samples were decreased by 88.7% and 87.6%, the porosities were decreased by 63.8% and 73.4%, and the micro-hardness values were increased by 41.7% and 32.7%, respectively. Furthermore, the two sorts of UB-treated coating samples exhibited better mechanical properties and wear resistance than corresponding untreated samples. Full article

(This article belongs to the Special Issue Laser Processing and Multi-Energy Field Manufacturing of High-Performance Materials)

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