Laser machining apparatus Patent
Laser machining device with dielectric functioning as beam waveguide for mechanical and medical applications
Chioa, R. Y.↗
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Laser Machining of Melt Infiltrated Ceramic Matrix Composite
As interest grows in considering the use of ceramic matrix composites for critical components, the effects of different machining techniques, and the resulting machined surfaces, on strength need to be understood. This work presents the characterization of a Melt Infiltrated SiC/SiC composite material system machined by different methods. While a range of machining approaches were initially considered, only diamond grinding and laser machining were investigated on a series of tensile coupons. The coupons were tested for residual tensile strength, after a stressed steam exposure cycle. The data clearly differentiated the laser machined coupons as having better capability for the samples tested. These results, along with micro-structural characterization, will be presented.
Jarmon, D. C.↗
Simulated Performance of Laser-Machined Metamaterial Anti-reflection Coatings
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N. Farias↗
Pointing stabilization of a 1 Hz high-power laser via machine learning
Abstract High-power lasers are vital for particle acceleration, imaging, fusion and materials processing, requiring precise control and high-energy delivery. Laser plasma accelerators (LPAs) demand laser positional stability at focus to ensure consistent electron beams in applications such as X-ray free-electron lasers and high-energy colliders. Achieving this stability is especially challenging for the low-repetition-rate lasers in current LPAs. We present a machine learning method that predicts and corrects laser pointing instabilities in real-time using a high-frequency pilot beam. By preemptively adjusting a correction mirror, this approach overcomes traditional feedback limits. Demonstrated on the BELLA petawatt laser operating at the terawatt level (30 mJ amplification), our method achieved root mean square pointing stabilization of 0.34 and 0.59 $\unicode{x3bc} \mathrm{rad}$ in the x and y directions, reducing jitter by 65% and 47%, respectively. This is the first successful application of predictive control for shot-to-shot stabilization in low-repetition-rate laser systems, paving the way for full-energy petawatt lasers and transformative advances across science, industry and security.
Amodio, Alessio↗
A six degrees of freedom femtosecond laser system for fabrication of small-scale mechanical property specimens
Here, we present the details of a novel ultra-short pulsed laser machining workstation that has been employed for high-throughput laser machining of small-scale mechanical property specimens. This system employs a six degrees of freedom hexapod positioning stage capable of macroscopic movements at high positional accuracy. We developed a methodology that uses quantitative image analysis to measure key parameters required to minimize the hexapod positioning and rotational error. Application of this system to laser machining of small-scale 316L stainless steel tensile specimens and ultra-high molecular weight polyethylene compressive specimens using eucentric tilt and rotation about the specimen axis will be shown, where serial laser milling at a specimen tilt angle of 10° was used to effectively eliminate any taper in the sample cross section that is typically found in laser machining.
47 OTHER INSTRUMENTATION↗
Fatigue Lives of Materials Cut by Lasers
Laser machining helps to balance high-speed rotating machinery. Report describes continuing studies of fatigue lives of materials cut by lasers. One long-term objective of such studies is use of laser machining to balance rotors operating at high speeds. To achieve objective, necessary to know relationship between effects of conventional and laser machining on fatigue lives of machined materials.
Martin, Michael R.↗
Efficient prediction of attosecond two-colour pulses from an X-ray free-electron laser with machine learning
Abstract X-ray free-electron lasers are sources of coherent, high-intensity X-rays with numerous applications in ultra-fast measurements and dynamic structural imaging. Due to the stochastic nature of the self-amplified spontaneous emission process and the difficulty in controlling injection of electrons, output pulses exhibit significant noise and limited temporal coherence. Standard measurement techniques used for characterizing two-coloured X-ray pulses are challenging, as they are either invasive or diagnostically expensive. In this work, we employ machine learning methods such as neural networks and decision trees to predict the central photon energies of pairs of attosecond fundamental and second harmonic pulses using parameters that are easily recorded at the high-repetition rate of a single shot. Using real experimental data, we apply a detailed feature analysis on the input parameters while optimizing the training time of the machine learning methods. Our predictive models are able to make predictions of central photon energy for one of the pulses without measuring the other pulse, thereby leveraging the use of the spectrometer without having to extend its detection window. We anticipate applications in X-ray spectroscopy using XFELs, such as in time-resolved X-ray absorption and photoemission spectroscopy, where improved measurement of input spectra will lead to better experimental outcomes.
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
Closed-Loop Control of Laser Surface Treatment via Laser Induced Breakdown Spectroscopy
Current composite manufacturing rates need to be improved to meet the projected demand of on-demand mobility (ODM) and commercial aircraft transports. Some processes in the composite manufacturing chain require touch labor such as manual sanding of surfaces prior to bonding and installing thousands of mechanical fasteners in bonded primary structures to achieve Federal Aviation Administration (FAA) certification. The consequences are insufficient repeatability in bond quality resulting in increased manufacturing time. The FAA has indicated that robust process control is one potential means of certifying bondlines in primary structure. This work describes an integrated closed-loop control system between a laser machining system and laser induced breakdown spectroscopy (LIBS) instrumentation as a means of assuring bond performance and achieving certified composite bondlines. Preliminary results from in-situ treatment and inspection are presented. Results indicate that LIBS inspection and laser treatment can be conducted simultaneously to achieve high quality, reliable adhesive bonds.
Rodolfo Ledesma↗
Closed-Loop Control of Laser Surface Treatment via Laser Induced Breakdown Spectroscopy
Current composite manufacturing rates need to be improved to meet the projected demand of on-demand mobility (ODM) and commercial aircraft transports. Some processes in the composite manufacturing chain require touch labor such as manual sanding of surfaces prior to bonding and installing thousands of mechanical fasteners in bonded primary structures to achieve Federal Aviation Administration (FAA) certification. The consequences are insufficient repeatability in bond quality resulting in increased manufacturing time. The FAA has indicated that robust process control is one potential means of certifying bondlines in primary structure. This work describes an integrated closed-loop control system between a laser machining system and laser induced breakdown spectroscopy (LIBS) instrumentation as a means of assuring bond performance and achieving certified composite bondlines. Preliminary results from in-situ treatment and inspection are presented. Results indicate that LIBS inspection and laser treatment can be conducted simultaneously to achieve high quality, reliable adhesive bonds.
Rodolfo Ledesma↗
Laser drilling and machining enhancement using gated CW and short pulsed lasers
The present disclosure relates to a laser system for processing a material. The system may make use of a laser configured to intermittently generate a first laser pulse of a first duration and a first average power, at a spot on a surface of the material being processed, and a second laser pulse having a second duration and a second peak power. The second duration may be shorter than the first duration by a factor of at least 100, and directed at the spot. The second laser pulse is generated after the first laser pulse is generated. The first laser pulse is used to heat the spot on the surface of the material, while the second laser pulse induces a melt motion and material ejection of molten material from the melt pool.
Ly, Sonny S.↗
Mechanisms of ultrafast GHz burst fs laser ablation
Gigahertz (GHz) femtosecond (fs) lasers have opened possibilities for enhancing and controlling the laser machining quality to engineer the physicochemical properties of materials. However, fundamental understanding of laser-material interactions by GHz fs laser has remained unsolved due to the complexity of associated ablation dynamics. Here, we study the ablation dynamics of copper (Cu) by GHz fs bursts using in situ multimodal diagnostics, time-resolved scattering imaging, emission imaging, and emission spectroscopy. A combination of probing techniques reveals that GHz fs bursts rapidly remove molten Cu from the irradiated spot due to the recoil pressure exerted by following fs pulses. Material ejection essentially stops right after the burst irradiation due to the limited amount of remnant matter, combined with the suppressed heat conduction into the target material. Our work provides insights into the complex ablation mechanisms incurred by GHz fs bursts, which are critical in selecting optimal laser conditions in cross-cutting processing, micro/nano-fabrication, and spectroscopy applications.
47 OTHER INSTRUMENTATION↗
Length scale effects of micro- and meso-scale tensile tests of unirradiated and irradiated Zircaloy-4 cladding
Zircaloy-4 is an essential material for cladding structures within fission-based reactors. To explore the changes in properties measured on differing length scales, FIB-machined micro-scale tensile tests were performed on both irradiated and control groups of Zircaloy-4. This was correlated with tensile testing on femtosecond laser-machined meso-scale specimens. Pronounced size effects were found when varying specimen geometry. Increases in tensile geometry size were associated with a reduction in measured yield stress for both irradiated and unirradiated samples. Here, meso-scale testing found strength and strain values similar to that of bulk-scale testing.
36 MATERIALS SCIENCE↗
Laser power transmission.
Description of studies which have led to the design of a conceptual device in which the limitation of transforming heat into coherent radiation can be examined. By exploring the basic thermodynamic relationships controlling the operation of this device, it is concluded that a closed-cycle gasdynamic laser is possible in which all of the shaft energy supplied can be turned into laser radiation. Hence, it is possible in principle to convert heat into coherent radiation with approximately the same efficiency with which heat may be converted into electricity. By modifying the closed-cycle-gasdynamic-laser system, this system can be operated in reverse and the incoming radiation may be used to pump the gas in the loop so that shaft power can be extracted. By carefully controlling the temperature distribution in this machine, laser energy can be converted into useful shaft energy with an efficiency approaching 1 .
Ahlstrom, H. G.↗
FY24 Integrated Results for High-Temperature Mechanical Testing of LPBF 316H Stainless Steel
This report provides the mechanical test data of laser powder bed fusion (LPBF) 316H stainless steel (SS) collected during Fiscal Year 2024 (FY 24) under the US Department of Energy, Office of Nuclear Energy’s Advanced Materials and Manufacturing Technologies program, along with the current state of microstructural-based understandings of the behaviors. Materials with variabilities in manufacturing site, machine, laser parameters, powder chemistry, porosity, specimen geometry and heat treatment were tested in high-temperature tension, creep, fatigue and creep-fatigue. Electron microscopy and optical microscopy were performed on selected materials before and after the tests to provide microstructural-based understandings to the mechanical behavior. It was discovered that the as-built (AB) and stress-relieved (SR) materials exhibit similar behaviors in tension and creep, as do the solution-annealed (SA) and hot-isostatic pressed (HIP) materials. The AB and SR materials are softer but more ductile than the SA and HIP materials in tension. In creep, the LPBF materials have comparable rupture times but lower rupture strains compared to the wrought materials. The AB and SR materials have low creep rupture strains (<10%) when tested at 720°C and 800°C, while the SA and HIP materials are much more ductile. The LPBF materials exhibit large scatter in fatigue and creep-fatigue lives. The cyclic lives of creep-fatigue tests are lower than those of fatigue tests. In fatigue and creep-fatigue, SR materials outperform SA materials. A common observation from the cyclic tests is that, given the same post-build heat treatment, a lower initial peak stress generally results in a longer cyclic life regardless of hold time. It was also discovered that the batch variation can be more impactful than heat treatment, as demonstrated by the overall better performance of one batch of material than another, regardless of the heat treatment. The results provided insights into how different factors impact the behaviors of LPBF 316H SS. An outlook to FY 25 work scope is provided.
36 MATERIALS SCIENCE↗
Laser micro-machining and damage testing of rounded shadow cone blockers on silica glass for arresting laser damage growth by redirection of light
Structured conical blockers manufactured on optical input surfaces are being used to shadow, and thereby, arrest growth of exit surface damage on large optics for applications in high-energy laser systems to extend their lifetime usage. However, as the size of the Shadow Cone Blocker (SCB) is increased, the deflected light must be carefully managed to prevent consequential damage from downstream intensification. Here, we design and fabricate a distinct input SCB geometry to alleviate this problem, enabling larger damage site mitigation. The demonstrated ~1 mm diameter SCB was manufactured with a convergent approach using a CO 2 pulsed laser ablative scanning sequence on a fused silica window. The SCB design was refined to maximize resistance to both input and exit surface damage initiations on 1 cm thick fused silica windows when exposed to 351 nm irradiation and validated with laser damage testing. The design showed to prevent damage onset to the exit surface for incident fluences on the SCB of 10.7 ± 1.3 J·cm -2 and is resistant to damage on the input surface exceeding 30 J·cm -2 input fluence.
36 MATERIALS SCIENCE↗
High-Rate Sputter Deposition of Ultrathick Boron Carbide Coatings on Rolling Spherical Substrates
Amorphous boron carbide (B 4 C) is a promising next-generation ablator material for inertial confinement fusion. However, the deposition of ultrathick B4C coatings with submicron-scale density uniformity on spherical substrates, as required for ablator shell fabrication, remains challenging. Here, in this study, we use direct current magnetron sputtering to deposit B 4 C onto 2-mm-diameter Si spheres rolling in a dish-shaped substrate holder. High deposition rates of ∼3 μm/h are achieved. Ultrathick films have a columnar microstructure, with the column width determined by the density of nodular defects. Nodular defect nucleation is dominated by the pickup of particulates from the holder during substrate rolling. We demonstrate the fabrication of a hollow B 4 C spherical shell with a wall thickness of 80 μm. Also demonstrated is the laser machining of holes in the B 4 C coating, which is necessary for both the chemical removal of the Si template and the attachment of a fusion fuel fill tube.
Inertial confinement fusion targets↗
Additive manufacturing of amorphous metal soft magnetic composites
Soft magnet alloys are used as magnetic cores for electric motors, transformers, wind turbines and other power generation systems. Soft magnetic cores are expensive and time consuming to manufacture in the complex shapes required for next-generation devices using conventional press and sinter powder metallurgy. The objective of this effort is to additively manufacture high performance soft magnets, with reduced cost and reduced material waste and 10x lower energy (core) loss at the high operating frequencies of many electric machines. Laser powder bed fusion additive manufacturing is used as the fabrication method. Electrical steel and amorphous alloys atomized powders are used as a feedstock materials. Magnetic cores are printed in topology optimized structures such as the Hilbert curve because this has been shown to reduce energy losses by minimizing the eddy currents that circulate within the magnet at high frequencies. In our project, we succeed in printing FeSi 3.5wt% and FeSi 6.5wt% electrical steels, and iron-based soft magnetic amorphous alloys in the shape of Hilbert and Peano curve topology optimized structures. We found that the Peano curve has a higher cut-off frequency than the Hilbert curve, and that amorphous alloys have high cut-off frequencies and higher mechanical hardness than electrical steels. Processing conditions such as laser power, scan speed, and hatching pattern were optimized to achieve high density prints, and optimize magnetic performance. We find that the printing of amorphous alloy soft magnetic cores may be technoeconomically feasible for large scale applications such as transformers, for which supply chain issues and the labor costs of manual fabrication of magnetic cores is prohibitive in some cases.
36 MATERIALS SCIENCE↗
Automatic inspection of silicon wafers
Laser machine scans wafers for contaminating particles which cause open circuits, short circuits, and other defects in integrated circuits and transfers good wafers to integrated circuit processing equipment. Machine is faster and more accurate than human operator using lightfield/dark field microscope.
Martin, M.↗