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- 2018
- Display Metrology
- dSiPM
- Quanta Image Sensor
- CMOS
- QIS
- Complementary Metal Oxide Semiconductor
- Digital Silicon Photo-Multiplier
- Single Photon Avalanche Diode
- SPAD
- metal object detection (MOD)
- Optoelectronic Information Science and Engineering
- Electrical Engineering and Automation
- The University of Edinburgh
- Shanghai Jiao Tong University
- STMicroelectronics Imaging Division
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A statistical learning method for image-based monitoring of the plume signature in laser powder bed fusion
摘要： The industrial breakthrough of metal additive manufacturing processes mainly involves highly regulated sectors, e.g., aerospace and healthcare, where both part and process qualification are of paramount importance. Because of this, there is an increasing interest for in-situ monitoring tools able to detect process defects and unstable states since their onset stage during the process itself. In-situ measured quantities can be regarded as “signatures” of the process behaviour and proxies of the final part quality. This study relies on the idea that the by-products of laser powder bed fusion (LPBF) can be used as process signatures to design and implement statistical monitoring methods. In particular, this paper proposes a methodology to monitor the LPBF process via in-situ infrared (IR) video imaging of the plume formed by material evaporation and heating of the surrounding gas. The aspect of the plume naturally changes from one frame to another following the natural dynamics of the process: this yields a multimodal pattern of the plume descriptors that limits the effectiveness of traditional statistical monitoring techniques. To cope with this, a nonparametric control charting scheme is proposed, called K-chart, which allows adapting the alarm threshold to the dynamically varying patterns of the monitored data. A real case study in LPBF of zinc powder is presented to demonstrate the capability of detecting the onset of unstable conditions in the presence of a material that, despite being particularly interesting for biomedical applications, imposes quality challenges in LPBF because of its low melting and boiling points. A comparison analysis is presented to highlight the benefits provided by the proposed approach against competitor methods.
关键词： Process plume,Metal additive manufacturing,Laser powder bed fusion,Infrared imaging,In-situ monitoring,Zinc
更新于2025-11-28 14:24:20
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Development of an Intra-Layer Adaptive Toolpath Generation Control Procedure in the Laser Metal Wire Deposition Process
摘要： Recently developed concentric laser metal wire deposition (LMWD) heads allow metal addition processes which are independent of the deposition direction, thus enabling complex paths to be generated. The sensitivity of the process to height deviations has experimentally been observed to be greater with this type of head than with powder ones, therefore requiring more precise and local process control algorithms to be implemented. This work developed a methodology for measuring the part, layer by layer, using a 3D scanner based on structured laser light. Height corrections were applied to the mean and intra-layer height deviations by recalculating the deposition trajectories of the next layer to be deposited. Local height deviations were adjusted by varying the scanning speed, thus increasing the feed rate in the lower areas and decreasing it in the higher ones. Defects generated in the purpose, with height differences within the layer, were successfully corrected. A flat layer was re-established through the application of the control strategy. The internal integrity of the parts due to the scanning speed variation was analyzed, resulting in fully dense parts. The structured light measurement and height correction systems are found to be an affordable and time-efficient solution that can be integrated into an LMWD environment, thereby improving the process robustness.
关键词： cladding,coaxial wire feed,metal wire,additive manufacturing,monitoring,laser deposition,structured light scanning,height control
更新于2025-11-28 14:24:20
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Energy efficiency evaluation of metal laser direct deposition based on process characteristics and empirical modeling
摘要： Metal laser direct deposition (MLDD) is a typical process in additive manufacturing (AM), which permits the build of complex and fully dense metallic parts by using laser to melt the metal powder layer by layer. However, the process is characterized by high energy consumption and low energy efficiency. This paper established an empirical model to characterize the relationship between process parameters and energy efficiency for MLDD based on the essence of thermodynamics physical energy conversion. Additionally, a recognition method of cross-sectional profile of the deposited layer was achieved by adding tungsten carbide (WC) powder, which greatly improved the measurement reliability. Taguchi experiment and regression identification method were applied, and the relative error of the model was less than 10%. The results show that laser power has significant influence on the process energy efficiency of MLDD. The energy efficiency of single-track multi-layer stacking (SMS) process and multi-track single-layer lapping (MSL) process increased by 5.7% and 50.3%, respectively, under the optimal process parameter condition. The proposed model can be used effectively for the energy efficiency evaluation and offer the potential for improving the sustainability of MLDD.
关键词： Energy efficiency,Metal laser direct deposition (MLDD),Cross-sectional profile,Taguchi experiment
更新于2025-11-28 14:24:20
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Epitaxy and new stray grain formation mechanism during epitaxial laser melting deposition of Inconel 718 on directionally solidified nickel-based superalloys
摘要： The epitaxy behavior and stray grains (SGs) formation in the deposit during epitaxial laser melting deposition (E-LMD) of directionally solidified (DS) superalloys were investigated. Columnar dendritic structures were obtained by epitaxial solidification on the DS substrate. The deposit also remained the orientation of the substrate. The SGs at the fusion interface, which were hardly eliminated, were attributed to different SGs formation mechanisms. The SGs were divided into GB-SGs and MC-SGs by the distribution characteristics. The GB-SGs at the low-angle and high-angle grain boundaries with a new mechanism of dynamic recrystallization induced by accumulation of thermal strain and stress under repeated spatially variable heating and cooling. The MC-SGs around the carbides were related to the misoriented cellular crystal formation caused by the varied shape of the solid-liquid interface. The columnar to equiaxed transition (CET) was another mechanism of MC-SGs formation.
关键词： Stray grain,Nickel superalloys,Laser metal deposition,Recrystallization,Dynamic,Epitaxy,Microstructure
更新于2025-11-28 14:24:20
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Effects of phase transition temperature and preheating on residual stress in multi-pass & multi-layer laser metal deposition
摘要： To investigate the influences of phase transition temperature and preheating on the residual stress of multi-layer and multi-pass laser metal deposition (LMD), the multi-layer and multi-pass LMD, with and without preheating, were performed using five kinds of alloy with different phase transition features, and their residual stresses were measured using the hole drilling method. A finite-element (FE) model incorporating the phase transition was developed based on experimentally obtained physical property data. The results demonstrated that the low-temperature solid phase transition has a tensile stress relaxation effect, which leads to the formation of a compressive stress area. This relaxation effect was observed to decrease with the increase of the phase transition temperature. The high-temperature solid phase transition has no significant tensile stress relaxation effect during the multi-layer and multi-pass LMD process, which is different from the single track LMD. when the solid phase transition temperature is low, the preheating can improve the uniformity of the stress field only to a certain extent. However, when the preheating increases the lowest temperature of the thermal cycle and makes it higher than the starting point temperature of the solid phase transition, the tensile stress relaxation effect of the solid phase transition can be brought into full play.
关键词： Finite element analysis,Preheating,phase transition temperature,Residual stress,Laser metal deposition
更新于2025-11-28 14:24:20
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Hybrid laser-metal inert gas keyhole welding of thick steel/Al butt joints
摘要： Dissimilar joining of steel/Al joints has become more and more signi?cant in industrial applications with particular weight saving interest. However, directly welding of steel/Al joints even in thin thickness is very di?cult. In the present study, the hybrid laser-metal inert gas (MIG) source focused on the steel side in keyhole mode was introduced to weld steel/Al butt joints of 6 mm in thickness. E?ects of the laser o?sets on the weld shape, interface microstructures, and ultimate tensile strength (UTS) of the steel/Al joints were investigated. Sound steel/Al butt joints were obtained by using this hybrid laser-MIG keyhole welding process. By increasing the laser o?sets from 0.6 and 0.8 mm, the welds exhibited a better shape with a smooth appearance attributable to the reduced heat input. The positions through the thickness of the steel/Al joints played an important role in the morphology and thickness of the intermetallic compound (IMC) layers at the Al/weld interface. The IMC layers had a thick irregular morphology at the upper part and the lower part, while the layers at the middle part exhibited a relatively thin and uniform morphology. With some certain welding conditions, the Al/weld interface at the lower part of the steel/Al joints transformed to a welding-brazing mode from a fusion one. The island-shape structures were formed at the Al/weld interface, and the IMC layers were composed of Fe2Al5 layer and needlelike Fe4Al13 phases. The maximum UTS of 87.0 MPa was obtained at a laser o?set of 0.6 mm. Although the failure occurred in the IMC layers revealed a brittle fracture, the fracture morphology and locations were a mixed failure, which had a certain resistance to the crack propagation of the IMC layers.
关键词： laser-metal inert gas welding,ultimate tensile strength,keyhole welding,intermetallic compound,steel/Al joints
更新于2025-11-28 14:24:20
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Microstructural Characteristics of Laser Metal Deposited Magnesium Alloy AZ31
摘要： Up to now, only a limited amount of metallic materials is investigated for laser additive manufacturing (LAM). However, the demand to widen the application possibilities by enlarging the range of materials for LAM is growing fast. By now, titanium and aluminium alloys are in the focus of research. In contrast, magnesium alloys are rarely used in the field of additive manufacturing, although they possess a low density in combination with a high specific strength. Currently, magnesium structures are mainly produced by casting but during the last years, the use of wrought alloys also increased. A reason for the rare use of magnesium alloys for LAM technologies might be the high flammability of magnesium powders. This difficulty can be avoided by using magnesium wire for laser metal deposition (LMD). In the present study, the microstructural characteristics of a LMD processed AZ31 magnesium alloy are investigated. For this purpose, optical microscopy and scanning electron microscopy were used. With the help of EDX and EBSD analysis, a change of the chemical composition and micro texture with structure height was identified. The relationship of microstructure and local mechanical properties was investigated with the help of Vickers micro hardness testing. Based on the obtained results it can be concluded that the microstructural characteristics of laser additive manufactured magnesium alloys differ from those of titanium and aluminium alloys. Thus, a wider application spectrum of LMD and magnesium alloys can be opened up.
关键词： laser metal deposition,local mechanical properties,microstructure,magnesium alloy,wire,microtexture
更新于2025-11-28 14:24:20
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Tunable passively Q-switched ytterbium-doped fiber laser using MoWS2/rGO nanocomposite saturable absorber
摘要： We demonstrated a tunable Q-switched ytterbium-doped fiber laser (YDFL) using MoWS2/rGO nanocomposite as passive saturable absorber. Further, the Mo1?xWxS2/rGO nanosheets, with x proportion of 0.2, are synthesized using hydrothermal exfoliation technique. The proposed nanocomposite-PVA based thin film is fabricated by mixing the MoWS2/rGO nanosheets with polyvinyl alcohol (PVA). The fabricated thin film is sandwiched between two fiber ferrules to realize the proposed saturable absorber (SA). Further, the proposed MoWS2/rGO-PVA based thin film SA exhibits a fast relaxation time and a high damage threshold which are suitable to realize a Q-switched pulsed laser with a tunable wavelength range of 10 nm that extends from 1028 nm to 1038 nm. For the highest pump power of 267.4 mW, the generated Q-switched pulses exhibit a narrow pulse width of 1.22 μs, the pulse repetition rate of 90.4 kHz, the highest pulse energy of 2.13 nJ and its corresponding average power of 0.193 mW. To the best of author’s knowledge, this is the first realization of a tunable Q-switching fiber laser in a 1 μm wavelength using MoWS2/rGO nanocomposite saturable absorber.
关键词： Saturable absorber,Molybdenum,Tungsten disulfide,Q-switched fiber laser,Transition metal dichalcogenides
更新于2025-11-28 14:24:03
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High-power, high-spectral-purity GaSb-based laterally coupled distributed feedback lasers with metal gratings emitting at 2? <i> <b>μ</b> </i> m
摘要： We report on the fabrication of high-power, high-spectral-purity GaSb-based laterally coupled distributed feedback (LC-DFB) lasers emitting at 2 μm. Second-order Chromium-Bragg-gratings are fabricated alongside the ridge waveguide by lift off. Due to the introduction of gain coupling, the lasers exhibit a stable single mode operation [side-mode suppression ratio (SMSR) >40 dB] from 10 °C to 50 °C and the maximum SMSR is as high as 53 dB. At a heat-sink temperature of 10 °C, the lasers emit more than 40 mW continuous-wave in a single longitudinal mode. A high external quantum efficiency of 48% is obtained, resulting in a notable increase in power conversion efficiency peaking at 13%. The lasers achieve a comparable output power with that of the index-coupled LC-DFB lasers, while maintaining a better single mode performance. Thus, we prove the feasibility of the metal-grating LC-DFB structure to achieve high-power, frequency-stable semiconductor lasers through a simpler and much more convenient way.
关键词： metal gratings,high-spectral-purity,high-power,distributed feedback lasers,GaSb-based lasers
更新于2025-11-28 14:24:03
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Optical Nonlinearity of ZrS2 and Applications in Fiber Laser
摘要： Group VIB transition metal dichalcogenides (TMDs) have been successfully demonstrated as saturable absorbers (SAs) for pulsed fiber lasers. For the group comprising IVB TMDs, applications in this field remain unexplored. In this work, ZrS2-based SA is prepared by depositing a ZrS2 nanostructured film onto the side surface of a D-shaped fiber. The nonlinear optical properties of the prepared SA are investigated, which had a modulation depth of 3.3% and a saturable intensity of 13.26 MW/cm2. In a pump power range of 144–479 mW, the Er-doped fiber (EDF) laser with ZrS2 can operate in the dual-wavelength Q-switching state. The pulse duration declined from 10.0 μs down to 2.3 μs. The single pulse energy reached 53.0 nJ. The usage of ZrS2 as a SA for pulse generation in fiber lasers is presented for the first time. Compared to the experimental results of dual-wavelength Q-switched fiber lasers with two-dimensional (2D) materials, our laser performance was better. Our work indicates that the group comprising IVB TMD ZrS2 has bright prospects for nonlinear optical applications.
关键词： transition metal dichalcogenides,saturable absorbers,ZrS2
更新于2025-11-28 14:24:03