mool c. gupta - university of virginia school of ... · pdf filecharles l. brown department of...

Charles L. Brown Department of Electrical and Computer Engineering

Laser Based Manufacturing

Mool C. GuptaLangley Distinguished Professor & NSF I/UCRC Center Director

Department of Electrical & Computer Engineering

University of Virginia

Presentation to industrial members 3-3-10


National Science Foundation Center

For Laser Based Manufacturing

Center Mission --

Develop Science, Engineeringand Technology Base for

Laser and Plasma Processing of Materials, Devices and

Systems for Advanced Manufacturing


Partnership

Projects

Industry

Fed. LabsUniv.

State NSF

MembershipMembership

Membership

CIT

Overhead &

Facility

Funds& NationalRecognition

National Science Foundation Industry University Cooperative Research Center for Laser Based Manufacturing

University of Virginia University of Michigan-Ann Arbor

University of Illinois

Southern Methodist University


Industrial Advisory Board MembersNASA Langley Research Center

AREVA GroupNAVAIR

GE Global ResearchGE Aviation

General Motors R&DToyota USA

Lockheed Martin Halliburton

IMRANuvonyx

Trinity IndustriesArmy Research Office

Spectra PhysicsTRUMPF

Lee Laser, Inc., FL; Fruth Innovative Technologies, GmbH, Germany ;

http://www.splasers.com/index.html�

http://www.nasa.gov/�

http://www.areva.com/servlet/home-en.html�

http://upload.wikimedia.org/wikipedia/en/1/12/ARL_logo.png�

http://www.trumpf.com/3.start.html�


•Laser Material Interactions

•Process sensing, monitor and control

•Materials and metallurgical aspects

•Laser systems

•Optics and beam delivery systems

•Laser micromachining, welding, plasma processing and hybrid processes

•Micromachining. Welding, texturing, drilling, surface modification, cladding, shaping, alloying, cleaning, sintering

Various Aspects of Laser Based Manufacturing


•Laser cleaning of surfaces-(Navair- Boeing and Bell Helicopter)

•Laser notch formation- (Navair, NASA)

•Laser micromachining- (Siemens & formerly DuPont subsidiary)

•Laser induced compressive stresses-(AREVA Group)

•Laser sintering of oxidation resistant UHT materials-(AFOSR)

•Fiber based detection of high tempr. through luminescence (NASA)

•Real time monitoring of weld pool through laser imaging (AREVA)•Butterfly Color Formation-(Alcoa Corporation)

•Other : solar energy( laser fired contacts, laser doping, laser morphology control), nanocomposites (electrical conducting plastics through carbon nanotubes), optical sensors

LASER BASED RESEARCH PROJECTS•Laser surface texturing-(NSF, NASA)


Research Infrastructure• Laser and Optics Lab

– Two fiber lasers (IPG), 50 ns pulse width– High power CW diode laser (250W)– Fs laser– Two Nd-YAG laser (10 ns pulse width– Optical measurement equipment– Computer controlled stages and galvo systems

• Clean Room Facility for Microfabrication– Optical Lithography, e-Beam Lithography,

sputtering, e-beam deposition, ion etching• Characterization Facility- SEM, TEM, AFM, X-

ray…..• Sensor and Photovoltaic Device Fabrication

and Characterization Labs

Charles L. Brown Department of Electrical and Computer EngineeringDiode pump Solid state laser

Diode laser

IPG fiber laser

YAG laserYAG laser


Laser Texture-Experimental Setup

Wavelength: 800 nm

Pulse Repetition Rate: 1 KHz

Pulse Energy: 1 mJ


Laser Textured Surfaces


Applications

• Generation of large surface area • Light trapping properties

– High contrast marking, logos, serial #’s etc– Super hydrophobic– Thermal management– Surface texture, ice formation, flow– Bond strength improvement– Photovoltaics, bio-implants etc.

Publications: 1. "Pulse width effect in ultrafast laser processing of materials", Applied Physics A : Matls. Sci. & Processing, Applied Physics A, Vol. 81, 1257, (2005).2. “Semiconductor laser crystallization of a-Si:H on conducting tin oxide coated glass for solar cell and display applications”, Appl. Phys. A: Materials Science and Processing A80, 1077, (2005).3. B. K. Nayak, M.C. Gupta and K. W. Kolasinski, “Formation of nanotexture conical microstructures in titanium metal surface by femtosecond laser irradiation”, Applied Physics, A, vol 90, p. 399 (2008).


Laser Marking & Superhydrophobic Surfaces


Inconel 690 laser cladding on Inconel 600 for nuclear applicationsLaser Aided Manufacturing for Nuclear Energy

SEM cross-section

• Improve corrosion resistance of coolant pipes by laser claddinglower cost / higher processing speedgood adhesion & high densityminimal residual stress in base materialgood chemical/mechanical/thermal stability

avoid premature failure & enhance lifereduce repair costsmaintain generator safety, efficiency, and up-timetransfer technology of laser metal cladding

http://people.virginia.edu/~tcb9y/Gupta/AREVA/SMU4.wmv�


Laser Aided Manufacturing for Nuclear Energy


Laser Processing of Ultra High Temperature Ceramics

xy

Nd:YAG LaserMirror

Lens

Argon gas environment

Nd:YAG Laser

High power CW laser

Stage

Advantages:-Non-contact process, eliminating contamination from walls-Achieving extremely high temperature (>4000°C), and the control of rapid heating and cooling rates-Sintering to high density, with minimal post processing requirements

Objectives:-Provide basic understanding of laser sintering mechanism for ultra high temperature ceramics (UHTCs)-Fabrication of cladding layer and 3-D structures using UHTCs for Air Force applications.


Hybrid Processing of Ultra High Temperature Ceramics

Advantages:- Laser preheats sample to facilitate MW absorption.- Volumetric heating increases throughput.- High power allows faster processing.

Objectives:- Investigate feasibility for [laser + microwave] sintering of ultra high temperature ceramics (UHTCs)- Explore resonant interaction between multiple energy sources.- Improve sintered properties by decreasing grain growth.

CW Laser

MW


Laser + MW Processing of Ultra High Temperature Ceramics


Laser cleaning of Ti alloy Tubing’s used in aircrafts


Laser Cleaning and welding

1/2”

3/8”

1/4”

Objective: Evaluate feasibility of laser cleaning of Titanium for welding applications (no chemicals)


3/8”

X-ray Inspection


Laser Micro-machining EDM

Sharp notch tip● Smaller heat effected zone

Laser micro notch fabrication

NAVAIR


0.10 inch

0.125 inch

Objective: Produce sharp notches in aluminum metal surfaces for mechanical testing

NASA


750 mil / 30 mil

Objective: Demonstrate laser micromachining of slots in carbon nanofiber based polymer composites

NASA


Laser Drilled Hole in S.S. 153 µm thick

Fs Laser Micromachining

Laser Micromachining

Siemens

DuPont


LASER-DRIVEN COMPRESSIVE WAVE GENERATION

• Turbine Blade & Vessel in Power Plants• Medical applications

Laser Shot Peening


Example apparatus setup for weld pool optical imaging (ref 2)

Real time monitoring of weld pool surface

AREVA Group


Laser Imaging of Weld Pool Surface


Excitation laser beam

Fluorescent light beam

High temperature fluorescent film on optical fiber surface

Spectrometer

Laser

Monitoring of fluorescent light intensity and life time

Fiber Based High Temperature Sensor using Fluorescent Method

NASA


1 μm

Laser texturing

Laser notch formation

Laser sintering

Laser surface cleaning

Laser micromachining


CONCLUSIONS

•Lasers provide a competitive edge in manufacturing

•Significant growth is expected in Laser Based Manufacturing

•Benefits by UVa Collaboration:

•a long experience in laser based manufacturing and interaction with industry

•Excellent infrastructure in lasers, optics and materials/process analysis

•Educational/training in area of laser technology and its applications in manufacturing


NSF Center Board Member?

•$30k membership allows•Technical project for 1 year

•Access to center technology

•Interaction with all center board members

•Benefit from other NSF supported projects

mool c. gupta - university of virginia school of ... · pdf filecharles l. brown department of...

Documents