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At least 271 records · Page 15

Demonstration of and future perspective on scaling ultrafast-laser-ablation microstructuring of Li-ion battery electrodes to roll-to-roll production and large-format cells

This work demonstrates integration of an ultrafast laser onto a roll-to-roll machine, the laser structuring of a double-sided, 700 m long roll of graphite battery anode and its subsequent manufacture into 27 Ah prismatic cells. The electrode was ablated with a novel hybrid-microstructure composed of both hexagonally arranged pores for enhanced rate performance and channels for fast electrolyte wetting. Subsequently, this anode and a non-ablated baseline anode are paired with an NMC111 cathode for cell building and electrochemical characterization. Compared to the baseline, laser ablated cells demonstrated a reduction in soaking time of at least 60%, an improvement in fast charge capability with >30% more capacity accepted during 6C charging, and an extension of cycle life of >40% during 0.5C cycling. Further, a perspective is provided on scaling ultrafast laser ablation of battery electrodes to industrial throughputs. Additionally, lessons learned from this pilot-scale demonstration are provided in regards to optical architecture, debris removal, and system control. A techno-economic analysis is used to demonstrate that laser ablation can be integrated into existing electrode manufacturing facilities with only ≈$\$$1.3 per kWh increase (≈2%) in manufacturing cost. Preemptive electrode design for laser ablation is discussed as a further method for enhancing performance. Finally, an analysis of available laser systems and beam-scanning architectures is used to determine design requirements to scale process throughput to a state-of-the-art speed of 50 m min −1 . This analysis demonstrates that laser ablating Li-ion battery electrodes has multiple benefits to manufacturing and battery performance, that the technology already exists to achieve high laser-ablation throughputs, and that integrating ultrafast laser ablation to electrode manufacturing will not create a cost or processing bottleneck.

25 ENERGY STORAGE↗

An extended Vlasov–Fokker–Planck approach for kinetic simulations of laser plasmas

Vlasov–Fokker–Planck simulation codes occupy an important niche in modeling laser-produced plasmas, since they are well suited to studying the effect of collisions on electron kinetic phenomena, especially energy transport. One of the most important elements of energy transport is the absorption of laser light by the plasma; however, simulating this in detail requires resolving oscillations of the laser light, whose characteristic timescale is orders of magnitude shorter than the simulation time needed to study transport physics. For this reason, most Vlasov–Fokker–Planck codes used to study electron transport in laser plasmas rely on simplified models of the laser–plasma coupling. Their underlying assumptions nominally preclude their use for modeling laser light having short-scale structure in space or time, such as broadband lasers. In this work, we derive a more general computational framework suitable for arbitrarily structured laser fields. Furthermore, our approach is based on an extended set of Vlasov–Fokker–Planck equations that separately solve for the low- and high-frequency plasma response. We implement these extended Vlasov–Fokker–Planck equations in the spherical harmonic code K2 and demonstrate the performance of the method on several laser absorption test problems, with particular attention to the judicious selection of time steps, time integrators, and spherical harmonic truncation, according to the intensity and spectrum of the laser light under consideration. Comparison with the widely used Langdon absorption operator shows the Langdon operator performs remarkably well for predicting laser heating in the simple cases considered here, even in situations that would seem to violate its underlying assumptions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Improving the laser performance of ion beam sputtered dielectric thin films through the suppression of nanoscale defects by employing a xenon sputtering gas

Laser damage-prone precursors in high index materials such as hafnia are believed to be the primary limiter in the performance of dielectric multilayer films to advance ultra-high power and energy laser applications. Removing or suppressing these precursors is the key to fabricating laser damage resistant thin films for the enabling technologies. Early work has revealed that nanobubbles formed by entrapped argon (Ar) working gas in ion beam sputtering (IBS) produced hafnia films are primarily responsible for the onset of laser damage upon exposure to UV, ns-laser pulses. In this study, we demonstrate that the UV ns-laser damage onset of IBS produced hafnia films can be improved to 3.1 +/- 0.2 J/cm 2 by substituting the conventional Ar working gas with xenon (Xe), a nearly 1 J/cm 2 increase from that of the Ar produced hafnia films. In addition to the suppression of the overall point-defect density of the hafnia films, the reduction of the Xe entrapment eliminates the nanobubbles and the generation of plasmas that initiates the laser damage. The defect suppression and its correlation to the increase in laser damage threshold is revealed by the combined analysis of Rutherford backscattering spectroscopy, electron paramagnetic resonance spectroscopy, transmission electron microscopy, and laser damage testing. Monte Carlo simulations suggest a much smaller entrapment of Xe gas by comparison to Ar, which is attributed to the significant difference in the energy of the reflected neutrals (3X) which are likely to be implanted. These results provide an effective process route with a fundamental understanding for producing high laser damage resistant dielectric films for high power and high energy laser applications.

36 MATERIALS SCIENCE↗

X-ray Lasers: The evolution from Star Wars to the table-top [PowerPoint]

X-ray lasers have evolved from a Star Wars missile defense system to a table-top research tool: (1) LLNL proposes X-ray laser schemes in the 1970’s, (2) First X-ray lasers demonstrated in early 1980’s were nuclear pumped, (3) Demonstrated the world’s shortest wavelength, highest energy laser, (4) First laboratory X-ray laser demonstrated on Novette in 1984, (5) A decade of progress using the Nova laser (5 kJ) from 1985 to 1996, (6) X-ray lasers produced at the COMET table-top facility (<10 J) since 1997, (7) X-ray lasers used for plasma interferometry and other applications, (8) 10 Hz X-ray laser at 18.9 nm demonstrated in 2004 using 0.15 J drive, (9) 100 Hz X-ray laser at 13.9 nm produces 1 µJ of saturated output using 0.9 J drive from diode-pumped optical laser in 2014.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Tunable Laser-Plasma Amplifier (Final Report)

Exploration at the laser intensity frontier has always offered new avenues for physics and reaching beyond this frontier is a grand challenge. Present-day petawatt-class lasers provide focused intensities on target of 10 22 W/cm 2 , corresponding to electric fields of 200 TV/m, while laser-plasma amplification opens a route for focused intensities well above 10 23 W/cm 2 . Intensities in this range provide the ability to test quantum electrodynamics in the unexplored low-energy, strong-field regime where signatures for new physics may arise. The behavior of matter under such extraordinary conditions is a rich and fascinating subject, not only in its own right in fundamental plasma physics, but for the many potential applications that promise to enrich the natural sciences in the future, including compact electron-beam, ion-beam particle accelerators, and ultra-bright X-ray sources. Although laser systems are now under construction internationally to access intensities of 10 23 W/cm 2 , the current technologies used appear to be fundamentally limited to these intensities. The realization of intensities beyond 10 23 W/cm 2 using parametric amplification in plasmas promises a breakthrough in high-energy density physics. Parametric amplification using Raman scattering in a plasma could provide the enabling technology for the generation of ultra-high-power laser pulses, but a more complete understanding of the nonlinear optics of plasmas is required. There is a significant gap in well-diagnosed laser-plasma instability studies of nonlinear plasma-wave phenomena, which are critical to understand for future laser-plasma devices. To achieve an efficient laser-plasma amplifier, plasma waves must be driven to large amplitude where significant energy can be rapidly transferred from the pump to the seed over the pulse duration of the seed. Simulations suggest that this nonlinear pump depletion regime can be achieved in the “pi-pulse” amplification regime. While simulations show this optimal regime with efficient amplification, it has remained elusive in experiments and there is a growing consensus within the community that thermal effects and pump beam limitations prevent laser-plasma amplifiers from progressing through the linear regime into the nonlinear pump depletion regime. Previous experiments have been significantly limited by the laser power available at the necessary wavelengths for the seed laser; therefore, the amplification is required to start in the linear regime where it is sensitive to many deleterious effects. The enabling technology (currently unique to plasma-wave amplification in the world) at the University of Rochester is the ability to provide a seed pulse with sufficient power (4 mJ/100 fs seed) to immediately drive nonlinear plasma waves into the pi-pulse regime and to tune its wavelength to optimize the efficiency of energy transfer. This in combination with the state-of-the-art OMEGA heater beams providing multiple kilojoules in a nanosecond to sufficiently heat the plasma make this system distinct from previous studies. These heater beams will provide, for the first time in Raman amplification studies, a homogeneous electron temperature high enough to prevent pump beam propagation issues that have plagued previous experiments. These systems will provide a platform for driving electron-plasma waves into the nonlinear regime where pump depletion and pulse shortening are predicted to lead to high amplification efficiencies (>30%). The Team has made significant progress through prior support from DOE Fusion Energy Sciences [DOE Office of Science Award Number DE-SC0016253 (2016-2022)]. This includes twenty-two peer-reviewed manuscripts, one patent, ten contributed talks presented at international conferences, and research that was highlighted as invited talks at fifteen international conferences. The broader impacts of this research are evident in the support of early career scientists, two Ph.D. theses, four current graduate students, a Masters Project, two undergraduate researchers, and an underrepresented minority student hired through the California Alliance for Minority Participation who now works as a Research Engineer in the group. This research met all of the funded research objectives and the highlights from primary Raman amplification thrust of this work are discussed below and form the foundation for the proposed research.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Broadband Frequency Conversion of Spectrally Incoherent Pulses and Initial Laser-Plasma Instabilities Mitigation Experiments

There is a need for efficient broadband frequency conversion schemes from the infrared, where optical pulses are efficiently amplified by solid-state laser materials, to the ultraviolet, a wavelength range more suitable for inertial confinement fusion (ICF). The current schemes are inadequate for broadband, spectrally incoherent optical pulses composed of a large number of frequency components distributed over a large frequency range. Implementing novel technologies that generate optical pulses with a large number of spectral components improves the laser-target interaction. In particular, it has long been believed that broad bandwidth mitigates the electron-plasma-wave instabilities that generate suprathermal electrons, which degrade ICF performance by increasing the fuel adiabat and reducing the shell areal density. It is important to develop a platform to demonstrate hot electron suppression caused by the larger available bandwidth, which has not previously been feasible in the laboratory. Experimentally measuring and theoretically assessing these effects with adequately benchmarked simulation codes are paramount to the design and development of novel laser facilities aiming at producing energy via laser fusion. The Laboratory for Laser Energetics is building a new laser facility, the Fourth-generation Laser for Ultrabroadband eXperiments (FLUX), to generate high-energy nanosecond laser pulses with fractional bandwidth larger than 1% in the ultraviolet and perform combined experiments with the 60-beam Omega facility. This large increase in bandwidth from the ~ 0.1% currently available on high-energy laser systems, is achieved by combining amplification in nonlinear optical parametric amplifiers (OPAs) around 1053 nm (1w) with nonlinear frequency conversion to the ultraviolet (around 351 nm, 3w). The novel scheme for frequency conversion is based on the noncollinear sum-frequency generation (SFG) of the angularly dispersed amplified 1w output with a narrowband 2w pulse, which is also used to pump the OPA system. The proposal funded scientific and engineering studies necessary to implement this novel laser facility, accelerated the SFG deployment by funding additional project team resources (shop time, engineers, and technicians), and funded preliminary experiments on the Omega Laser.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Path Length Matching and Phase control for Coherently Combined Fiber Laser Arrays (1DPATH)

Coherently combined fiber lasers are literally the future of all lasers. Through coherent combining the high efficiency, ruggedness, and low cost of fiber lasers can be synthesized into any laser imaginable. Lasers of any wavelength, pulse characteristics, energy, average power, or beam output shape can be created through the coherent combination of a low cost base fiber laser. We now have the opportunity to move from traditional “Analog” lasers with their bulk optics, big optical benches, strict cleanliness requirements and high cost and fragility towards “Digital Lasers” where the output beams are shaped to provide characteristics like Orbital Angular Momentum to not only specify the traditional laser characteristics but also the output beam patterns as well. This will enable future applications such as Wakefield Accelerators, petawatt lasers, particle beam control, as well as Inertial Confinement Fusion Drivers and a host of other medical, scientific, and industrial uses.

42 ENGINEERING↗

Picosecond laser generated plasma as a source of singly charged ions for external injection into an EBIS

The focus of this paper is on practical aspects of ion generation by picosecond lasers as a source of low charge state ions for external injection of ions into an electron beam ion source (EBIS). For a ps-laser, compared to a ns-laser currently used at Relativistic Heavy Ion Collier Electron Beam Ion Source (RHIC EBIS), the influence of heat conductivity in the solid target is almost negligible, which results in a lower target consumption rate and less vacuum pressure rise. By using a laser with high repetition rate, it is possible to produce quasi continuous 1+ ion beams for periods of tens of milliseconds, making it possible to take advantage of the ability of the EBIS to accumulate ions in the “slow” injection capture mode. Producing such an ion pulse train is now feasible since ps-lasers with pulse energy up to 10 mJ and rep-rate up to 10 kHz have recently become commercially available. The advantages of this lower current accumulation scheme include: (1) easier beam transport due to lower space charge of lower beam currents required compared to the present single pulse fast injection scheme, (2) better EBIS pulse to pulse ion output stability since pulse to pulse ion variations of the laser source are averaged over a long train of laser pulses, and (3) the possible addition of an isotope separator in which rare beams could be produced and selected at run time from less expensive (unenriched) targets. We studied the properties of plasmas generated by a ps-laser with 1.27 mJ energy within an 8 ps pulse and a repetition rate up to 400 Hz at Argonne National Laboratory to investigate feasibility and specify parameters for a laser ion source for RHIC EBIS using a “slow” injection mode. Al, Ti, Cu, Nb, and Ta targets were tested with various target translation speeds. Here, we demonstrated that a both “slow” and “fast” injection modes are accessible with a single ion source geometry and single injection line, providing the most attractive option for an ion source for external injection into RHIC EBIS trap based on a ps-laser.

43 PARTICLE ACCELERATORS↗

Laser-interference pulse number dependence of surface chemistry and sub-surface microstructure of AA2024-T3 alloy

The laser-based treatment of a metal surface is an intrinsically non-chemical technique that can alter both the topology and chemistry of surfaces. A laser-based treatment for coating and joining applications can offer alternative surface preparations to the chemically-based surface preparation techniques, which are subject to severe environmental protection and hazardous-waste management considerations. In this study, the surface chemistry and sub-surface microstructural changes are investigated for a novel surface processing method using laser interferometry produced by two beams of a pulsed Nd:YAG laser. The two-beam laser-interference allowed the structuring of the surface at length scales much less than that of the laser beam spot. Surface chemistry changes in the oxide layer of AA 2024-T3 aluminum alloy rolled sheet due to laser processing were investigated using x-ray photoelectron spectroscopy (XPS). Near surface microstructural changes have been investigated with scanning electron microscopy and energy dispersive x-ray spectroscopy (SEM/EDS), and scanning transmission electron microscopy (STEM) as a function of number of interfering laser shots. SEM microstructure pictures of the top surface shows the minimization of surface defects, as all of the sharp features from a rolled sheet surface were smoothed by laser-structuring. STEM images indicate that the laser-interference processing reduced the formation of CuMn-rich precipitates over a 500–800 nm depth from the top surface. XPS data indicated that the Al oxide layer is modified compared to that of the baseline specimen and that the oxide thickness increases with the number of shots per spot. Finally, the additional thicker oxide on Al alloys is expected to increase the corrosion resistance of the coated Al 2024.

36 MATERIALS SCIENCE↗

Off-harmonic optical probing of high intensity laser plasma expansion dynamics in solid density hydrogen jets

Due to the non-linear nature of relativistic laser induced plasma processes, the development of laser-plasma accelerators requires precise numerical modeling. Especially high intensity laser-solid interactions are sensitive to the temporal laser rising edge and the predictive capability of simulations suffers from incomplete information on the plasma state at the onset of the relativistic interaction. Experimental diagnostics utilizing ultra-fast optical backlighters can help to ease this challenge by providing temporally resolved inside into the plasma density evolution. We present the successful implementation of an off-harmonic optical probe laser setup to investigate the interaction of a high-intensity laser at 5.4 x 10 21 W/cm 2 peak intensity with a solid-density cylindrical cryogenic hydrogen jet target of 5μm diameter as a target test bed. The temporal synchronization of pump and probe laser, spectral filtering and spectrally resolved data of the parasitic plasma self-emission are discussed. The probing technique mitigates detector saturation by self-emission and allowed to record a temporal scan of shadowgraphy data revealing details of the target ionization and expansion dynamics that were so far not accessible for the given laser intensity. Plasma expansion speeds of up to (2.3 ± 0.4)x 10 7 m/s followed by full target transparency at 1.4ps after the high intensity laser peak are observed. A three dimensional particle-in-cell simulation initiated with the diagnosed target pre-expansion at -0.2ps and post processed by ray tracing simulations supports the experimental observations and demonstrates the capability of time resolved optical diagnostics to provide quantitative input and feedback to the numerical treatment within the time frame of the relativistic laser-plasma interaction.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Experimental studies of 1.5 – 1.6 μm high-power single-frequency semiconductor lasers

High-power semiconductor laser systems based on 1.5 – 1.6 μm single-frequency distributed feedback (DFB) lasers with a sidewall Bragg diffraction grating are developed and their current – voltage, light – current, and spectral characteristics are experimentally studied. The characteristics of conventional lasers with a Fabry – Perot cavity and DFB lasers fabricated from one and the same heterostructure are compared. At a pump current not exceeding 700 mA, a conventional laser with a cavity length of 1.6 mm and a mesa-stripe width of 3 μm emits a power no lower than 200 mW versus 150 mW of the DFB laser; both lasers are mounted in a housing 11 mm in diameter. The DFB laser mounted in a butterfly housing emits a power no lower than 100 mW at the exit of the single-mode cable at a pump current not exceeding 500 mA, which, at a 60 % coupling efficiency, corresponds to a power no lower than 165 mW; the side-mode suppression ratio in this case is no lower than 53 dB. It is shown that the wavelength deviation with changing pump current and temperature is almost an order of magnitude lower for the DFB laser than for the conventional laser. (paper)

36 MATERIALS SCIENCE↗

The effect of blue and infrared laser melting frequency on oxide morphology in 304L

Continuous Wave Laser Beam (LB) melting offers control over the localised heating and cooling of melt pools for welding, brazing, additive manufacturing and solidification. Research into laserliquid metal interactions has primarily focused on the heat and mass transport under large thermal gradients imposed by the localised melting conditions. Recent commercial availability of blue (450 nm) wavelength lasers has enabled the printing of material with poor IR (1064) nm attenuation like Cu. However, little research has been conducted into varying input laser frequency and scan rate at fixed absorption to understand the effects of laser light on surface oxide formation and the underlying liquid metal thermodynamic response. Here, this article conducts laser melting of 304L under Blue (450 nm) and Infrared (IR, 1064 nm) laser frequencies and examines their impact on laser oxide thickness, chemistry and coloration. We find that laser frequencies induce changes in the oxide layer thickness and chemistry that cannot be explained using conventional thermal absorption shifts and fluid dynamics. We suggest that light coupling may have thermodynamic implications for the chemical potential of the liquid metal, which may drive the observed phase behaviour. Identifying mechanisms for the tuning of the chemical potential via laser frequency control could enable the ability to control solidification microstructure and atomic ordering in laser welding and additive manufacturing processes.

304L↗

Next steps in high-repetition-rate laser development for Thomson scattering

Design of a next generation high-rep-rate laser system is underway, aiming for a maximum rep rate of 100 kHz for 1 ms. This will be a "pulse-burst" laser, which is a type of heat-capacity laser. Heat-capacity laser operation is characterized by a burst of pulses of limited duration, with burst length ≤100 ms and pulse rep rate ≥1 kHz. Waste heat accumulates in the laser rod during the burst. This heat is deposited evenly throughout the rod volume, with very little heat removed during the burst, such that temperature rises evenly across the rod radius. Thus beam distortion due to thermal gradients is small. Heat is removed from the rod after the burst, with typically tens of seconds between bursts. Pulse-burst operation of flashlamp pumped Nd:YAG lasers is a cost-effective route to high-rep-rate capability. Pulse-burst laser systems with "fast burst" rep rates in the range of 10–20 kHz have been built for the Thomson scattering diagnostics on MST, NSTX-U, and LHD. For Thomson scattering diagnostic application, the typical requirements are 1064 nm, 1–2 J/pulse, ≤30 ns FWHM pulse, with a top-hat beam profile. A major requirement for this next generation laser system is flexibility in burst sequence programs, ranging from 1 kHz for 100 ms to 100 kHz for 1 ms, and a variety of scenarios in between so that operation can be tailored to plasma experiment requirements. Flashlamp pumping will be used for this next generation laser because it is inexpensive and flexible. A new switch-regulated flashlamp driver will provide improved flashlamp control at lower cost. Additional design issues such as the optimum flashlamp pumping spectrum and optimum Nd doping will be addressed. The use of commercial off-the-shelf components will be maximized in this laser system so that pulse-burst systems can be developed and built by others for new applications.

47 OTHER INSTRUMENTATION↗

Direct Acceleration of an Electron Beam with a Radially Polarized Long-Wave Infrared Laser

Direct laser acceleration with radially polarized lasers is an intriguing variant of laser-based particle acceleration that has the potential of offering GeV/cm-level energy while avoiding the instabilities and complex beam dynamics associated with plasma wakefield accelerators. A major limiting factor is the difficulty of generating high-power radially polarized beams. In this paper, we propose the use of CO2-based long-wave infrared (LWIR) lasers as a driver for direct laser acceleration, as the polarization insensitivity of the gain medium allows a radially polarized beam to be amplified. Additionally, the larger waist sizes, Rayleigh lengths, and pulse lengths associated with the long wavelength could improve the injection efficiency of the electron beam. By comparing acceleration simulations using a near-infrared laser and an LWIR laser, we show that the injection efficiency is indeed improved by up to an order of magnitude with the longer wavelength. Furthermore, we show that even sub-TW peak powers with an LWIR laser can provide MeV-level energy gains. Thus, radially polarized LWIR lasers show significant promise as a driver of a direct laser-driven demonstration accelerator.

43 PARTICLE ACCELERATORS↗

Corrosion Behavior of Laser-Interference Structured AA2024 Coated with a Chromate-Containing Epoxy Primer

In this study, the corrosion behavior of laser-interference treated AA2024-T3 specimens, which are coated with a primer, is presented. The surface of as-received AA2024-T3 specimens were laser-interference structured by splitting the primary beam of a Q-switched Nd:YAG pulsed nanosecond laser into two beams and focusing them to the same spot on the specimen surface. After being stored in plastic cases for up to 70 d, without any additional cleaning, the specimens were spray painted with a chromate-containing epoxy primer, CA7233, compliant to MIL-PRF-23377 Type I Class C2 specification. The corrosion behavior of laser-interference specimens was assessed against that of specimens prepared by chromated conversion coating and sulfuric acid anodizing treatments. After the ASTM B117 corrosion exposure, it was found that the laser processed specimens exhibited only few blisters. On one hand, most specimens prepared at a laser fluence of 1.78 J/cm 2 , without any additional chemical cleaning, were found to develop one very small blister after only 96 h of exposure. However, the growth of these blisters was not significant even after 1,000 h of salt spray exposure. On the other hand, only a fraction of the specimens prepared at a laser fluence of 1.24 J/cm 2 and acetone wiped right after the laser structuring were found to develop several tiny blisters after 790 h and longer exposure. Overall, it was found that the corrosion damage was minimized at a laser rastering speed of 4 mm/s, a condition for which only 33% of specimens developed very minor corrosion damage. Furthermore, the ASTM D1654 creepage ratings, which was used to evaluate the corrosion damage along the scribe lines, were found to be at least nine for all coated panels. These results indicate that the laser-interference technique with the additional acetone wiping has the potential to be further developed as a nonchemical surface preparation technique for chromate-containing epoxy primers coating systems.

36 MATERIALS SCIENCE↗

The causal relationship between melt pool geometry and energy absorption measured in real time during laser-based manufacturing

During laser powder bed fusion additive manufacturing, laser power absorption is governed by a pro -tean pool of molten metal that can present as a highly reflective surface, a deeply absorbing cavity, or some amalgamation thereof. These melt pool dynamics have been linked to defect creation, porosity, and surface finish quality. Although these are therefore critical for determining final part quality, their in-stantaneous influence on laser absorption have only been explored through simulation. To date, direct real-time observations have been elusive due to the locally extreme environment. In this work, we fo-cus a laser on Ti-6Al-4V powder and bare plate while quantifying the time-dependent, absolute energy absorption by monitoring omnidirectional backscattered laser intensity. We also simultaneously record the projective melt pool geometries with high-speed synchrotron x-ray imaging. We find that laser ab-sorption strongly reflects the stability of the vapor depression over a wide range of applied laser powers, oxygen content in the processing atmosphere, and with the presence of powder. During laser scanning of a powder bed surface, we find a significant absorption reduction after 400 mu s due to a dramatic change in the vapor depression aspect ratio-an event known to create porosity. Furthermore, as several industrial scan strate-gies necessitate thousands of these events during a build, their identification and control is of significant practical importance. Lastly, a normalized enthalpy model is demonstrated to be effective in quantifying the relationship between the laser absorption and cavity depth, even under transient conditions. In addi-tion to providing vital quantitative data for simulation calibration, the correlation of melt pool geometry with laser absorption during realistic processing conditions suggests the use of a total backscattered light detection system for real-time process control.

36 MATERIALS SCIENCE↗

Understanding process-microstructure-property relationships in laser powder bed fusion of non-spherical Ti-6Al-4V powder

Powder feedstock is a major cost driver in metal additive manufacturing (AM). Replacing the spherical powder with the cost-efficient non-spherical one can reduce the feedstock cost up to 50% and attract more interest to adopt AM in production and new alloy development. Here, for this paper, a comprehensive study was conducted to understand process-microstructure-property relationships in laser powder bed fusion of hydride-dehydride Ti-6Al-4V powder. We demonstrated that variation of laser scan speed had a significant impact on the grain structure, pore evolution and properties compared to laser power. Dynamic X-ray radiography showed that with decreasing scan speed at a constant laser power, a transition from conduction to keyhole mode laser processing occurred, in which a deeper melt pool at lower scan speed intensified texture. In other words, an increase in laser scan speed resulted in formation of the refined prior β grains with shape factor of ~5, lowering the anisotropy. Furthermore, the degree of variant selection was evaluated based on the analyzed texture as a function of laser power and scan speed. With increasing laser scan speed, the dominant α/α boundary type was altered from type 2 to 4 and the degree of variant selection was noticeably decreased. On the other hand, increasing laser power left the morphology of prior β grains, their size, and the dominant α/α boundary (type 4) unchanged, while the texture and anisotropy were intensified, and the degree of variant selection was slightly decreased. Finally, dependency of surface roughness and microhardness were discussed as a function of laser processing parameters.

variant selection↗

Turnkey locking of quantum-dot lasers directly grown on Si

Ultralow-noise laser sources are crucial for a variety of applications, including microwave synthesizers, optical gyroscopes and the manipulation of quantum systems. Silicon photonics has emerged as a promising solution for high-coherence applications due to its ability to reduce the system size, weight, power consumption and cost. Semiconductor lasers based on self-injection locking have achieved fibre laser coherence, but typically require a high-quality-factor external cavity to suppress coherence collapse through frequency-selective feedback. Lasers based on external-cavity locking are a low-cost and turnkey operation option, but their coherence is generally inferior to self-injection locking lasers. In this work, we demonstrate quantum-dot lasers grown directly on Si that achieve self-injection-locking laser coherence under turnkey external-cavity locking. The high-performance quantum-dot laser offers a scalable and low-cost heteroepitaxial integration platform. Moreover, the chaos-free nature of the quantum-dot laser enables a 16 Hz Lorentzian linewidth under external-cavity locking using a low-quality-factor external cavity, and improves the frequency noise by an additional order of magnitude compared with conventional quantum-well lasers.

Dong, Bozhang↗