Laser Fabrication and Machining of Materials

by Dahotre, Narendra B.; Harimkar, Sandip P.

• ISBN13: 9780387723433
• ISBN10: 0387723439
• Format: Hardcover
• Copyright: 2007-12-01
• Publisher: Springer Verlag

Summary

This book will cover fundamental principles and the physical phenomena behind laser-based fabrication/machining processes, as well as their existing and potential applications. It provides a link between advanced materials and advanced processing/manufacturing techniques. Laser machining is an emerging area in various applications ranging from bulk machining in metal forming to micomachining and microstructuring. This book provides a comprehensive overview of the principles and applications of lasers applied to material removal processes in manufacturing, micromachining, and medial applications. The emerging field of laser assisted machining and machining using intersecting beams will also be covered. The interdisciplinary approach to these topics, as well as the ranging subject matter will help prepare students and researchers for the next generation of manufacturing.

Author Biography

Narendra B. Dahotre is a Professor with joint appointment with Oak Ridge National Laboratory and Department of Materials Science and Engineering of the University of Tennessee-Knoxville. He is also Chairman of the Center for Laser Applications at the University of Tennessee Space Institute-Tullahoma. Dr. Dahotre is author, co-author of over 80 technical articles and editor of 11 technical books. He holds 15 US patents in laser materials processing. He has organized 12 symposia and conferences in the area of Surface Engineering and High Temperature Coatings. He has successfully conducted several research projects funded by government and private industry in the field of laser surface engineering. His current research continues to be in laser based surface engineering. He is a member of TMS, ASM, SME, and AAAS. He is a joint Chair of the Surface Engineering Committee of TMS and a member of ASM international Surface Engineering Task Force.

Table of Contents

Fundamentals of Laser Processing	p. 1
Basics of Lasers	p. 3
Introduction	p. 3
Nature of Electromagnetic Radiation	p. 3
Laser Operation Mechanism	p. 6
Population Inversion	p. 6
Stimulated Emission	p. 8
Amplification	p. 9
Properties of Laser Radiation	p. 13
Monochromaticity	p. 13
Collimation	p. 15
Beam Coherence	p. 16
Brightness or Radiance	p. 17
Focal Spot Size	p. 17
Transverse Modes	p. 18
Temporal Modes	p. 20
Frequency Multiplication	p. 22
Types of Industrial Lasers	p. 23
Solid-State Lasers	p. 24
Gas Lasers	p. 25
Semiconductor Lasers	p. 27
Liquid Dye Lasers	p. 31
Laser Materials Interactions	p. 34
Introduction	p. 34
Absorption of Laser Radiation	p. 34
Thermal Effects	p. 40
Heating	p. 40
Melting	p. 43
Vaporization	p. 45
Important Considerations for Thermal Analysis	p. 50
Vapor Expansion and Recoil Pressures	p. 55
Plasma Formation	p. 59
Ablation	p. 61
Laser Machining	p. 67
Manufacturing Processes: An Overview	p. 69
Introduction	p. 69
Manufacturing Processes	p. 69
Casting Processes	p. 70
Forming Processes	p. 71
Joining Processes	p. 74
Machining Processes	p. 75
Lasers in Manufacturing	p. 79
Laser Casting	p. 79
Laser Forming/Shaping	p. 80
Laser Joining	p. 83
Laser Machining	p. 84
Selection of Manufacturing Processes	p. 85
Properties of Materials	p. 85
Geometrical Complexity of Product	p. 88
Quality Parameters	p. 90
Manufacturing Economics	p. 92
Laser Drilling	p. 97
Introduction	p. 97
Laser Drilling Approaches	p. 98
Melt Expulsion During Laser Drilling	p. 99
Analysis of Laser Drilling Process	p. 103
Quality Aspects	p. 117
Practical Considerations	p. 124
Effect of Laser Parameters	p. 125
Effect of Focusing Conditions	p. 128
Effect of Assist Gas Type, Gas Pressure, and Nozzle Design	p. 129
Laser Drilling Applications	p. 134
Drilling of Cooling Holes	p. 134
Drilling of Diamonds	p. 136
Microdrilling	p. 136
Advances in Laser Drilling	p. 137
Laser Cutting	p. 144
Introduction	p. 144
Laser Cutting Approaches	p. 145
Evaporative Laser Cutting	p. 146
Laser Fusion Cutting	p. 152
Reactive or Oxygen-Assisted Laser Cutting	p. 158
Controlled Fracture Technique	p. 167
Quality Aspects	p. 171
Striations	p. 171
Dross	p. 176
Heat-Affected Zone	p. 179
Practical Considerations	p. 183
Effect of Laser Type	p. 183
Effect of Laser Power	p. 183
Effect of Optical System	p. 186
Effect of Nozzle Parameters	p. 187
Effect of Assist Gas Type	p. 190
Laser Cutting of Various Materials	p. 193
Metallic Materials	p. 193
Polymers	p. 197
Ceramics and Glasses	p. 198
Laser-Cutting Applications	p. 200
Advances in Laser Cutting	p. 200
Laser Cutting Assisted by Additional Energy Sources	p. 200
Underwater Cutting	p. 201
Laser Cutting of Composites and Laminates	p. 202
Three-Dimensional Laser Machining	p. 207
Introduction	p. 207
Laser-Assisted Machining	p. 207
LAM Process	p. 208
Analysis of LAM Process	p. 209
LAM Process Results	p. 215
Laser Machining	p. 225
Machining Using Single Laser Beam	p. 225
Machining Using Intersecting Laser Beams	p. 233
Applications of Three-Dimensional Laser Machining	p. 243
Laser Micromachining	p. 247
Introduction	p. 247
Laser Micromachining Mechanisms	p. 247
Laser Ablation	p. 248
Laser-Assisted Chemical Etching	p. 260
Laser Micromachining Techniques	p. 265
Direct Writing Technique	p. 265
Mask Projection Technique	p. 267
Interference Technique	p. 268
Combined Techniques	p. 270
Laser Micromachining Applications	p. 271
Microvia Drilling	p. 271
Drilling of Inkjet Nozzle Holes	p. 272
Resistor Trimming	p. 273
Laser Scribing and Dicing	p. 276
Laser Marking and Engraving	p. 277
Biomedical Applications	p. 280
Thin Film Applications	p. 282
Fuel Injector Drilling	p. 283
Stripping of Wire Insulation	p. 285
Laser Fabrication	p. 289
Laser Forming	p. 291
Introduction	p. 291
Laser Forming Processes	p. 292
Bending or Temperature Gradient Mechanism	p. 294
Buckling Mechanism	p. 296
Upsetting Mechanism	p. 299
Analysis of Laser Forming Processes	p. 299
Temperature Gradient Mechanism	p. 300
Buckling Mechanism	p. 308
Practical Considerations	p. 312
Processing Parameters	p. 312
Bending Rate and Edge Effects	p. 323
Laser Forming Strategies and Control	p. 329
Microstructure and Properties of Laser-Formed Components	p. 337
Laser Forming Applications	p. 341
Correction of Bending Angles	p. 341
Laser Forming of Complex Shapes	p. 341
Rapid Prototyping	p. 343
Flexible Straightening of Car Body Shells	p. 343
Microfabrication	p. 344
Laser Forming in Space	p. 344
Advances in Laser Forming	p. 344
Laser Forming of Tubes	p. 344
Laser Forming with Preload	p. 347
Laser Forming with Two Beams	p. 348
Laser Forming of Composite Materials	p. 349
Laser-Based Rapid Prototyping Processes	p. 353
Introduction	p. 353
Basics of Rapid Prototyping Processes	p. 353
Classification of Rapid Prototyping Processes	p. 355
Liquid-Based RP Processes	p. 356
Powder-Based RP Processes	p. 357
Solid-Based RP Processes	p. 358
Concept Modelers	p. 359
Laser-Based Rapid Prototyping Processes	p. 359
Stereolithography	p. 359
Selective Laser Sintering	p. 379
Laminated Object Manufacturing (LOM)	p. 397
Laser Engineered Net Shaping (LENS)	p. 402
Applications of Rapid Prototyping Processes	p. 405
Applications in Rapid Prototyping	p. 406
Applications in Rapid Tooling	p. 407
Applications in Rapid Manufacturing	p. 407
Medical Applications	p. 407
Laser Welding	p. 412
Introduction	p. 412
Laser Welding Process	p. 412
Analysis of Laser Welding Process	p. 415
Quality Aspects	p. 427
Porosity	p. 427
Cracking	p. 429
Heat-Affected Zone	p. 431
Mechanical Properties of Laser Welds	p. 432
Practical Considerations	p. 433
Effect of Laser Parameters	p. 433
Effect of Focusing Conditions	p. 435
Effect of Shielding Gas	p. 435
Effect of Welding Speed	p. 437
Joint Configurations	p. 437
Laser Welding of Various Materials	p. 438
Metallic Materials	p. 438
Ceramics	p. 439
Polymers	p. 440
Composites	p. 440
Dissimilar Materials	p. 442
Advances in Laser Welding	p. 443
Arc-Augmented Laser Welding	p. 443
Multibeam/Dual-Beam Laser Welding	p. 443
Laser Welding of Tailor-Welded Blanks	p. 444
Special Topics in Laser Processing	p. 449
Laser Interference Processing	p. 451
Introduction	p. 451
Theory of Interference	p. 451
Interferometry for Surface Processing of Materials	p. 453
Laser and Materials Aspects	p. 454
Interferometer Design Aspects	p. 456
Applications of Laser Interference Processing	p. 459
Crystallization and Structuring of Semiconductor Films	p. 459
Structuring of Monolayer and Multilayer Metallic Films	p. 464
Structuring of Biomaterials	p. 472
Laser Shock Processing	p. 477
Introduction	p. 477
Fundamentals of Laser Shock Processing	p. 477
Analysis of Laser Shock Processing Process	p. 480
Processing Parameters	p. 484
Effect of Laser Intensity	p. 484
Effect of Pulse Duration	p. 484
Effect of Temporal Pulse Shape	p. 486
Effect of Laser Wavelength	p. 486
Effect of Spatial Energy Distribution	p. 488
Effect of Coating Material	p. 489
Mechanical Effects During Laser Shock Processing	p. 491
Microstructure Modification During Laser Shock Processing	p. 493
Applications of Laser Shock Processing	p. 496
Laser Dressing of Grinding Wheels	p. 499
Introduction	p. 499
Grinding Process and Need of Wheel Dressing	p. 499
Laser-Based Wheel Dressing Techniques	p. 502
Laser-Assisted Dressing	p. 502
Laser Dressing	p. 506
Recent Approaches of Laser Dressing	p. 511
Lasers Processing in Medicine and Surgery	p. 522
Introduction	p. 522
Laser-Tissue Interactions	p. 522
Photothermal Interactions	p. 526
Photochemical Interactions (Photoablation)	p. 529
Photodisruptive Interactions	p. 532
Laser Applications in Medicine and Surgery	p. 534
Lasers in Ophthalmology	p. 534
Lasers in Dermatology	p. 540
Lasers in Otolaryngology-Head and Neck Surgery	p. 545
Lasers in Angioplasty	p. 545
Lasers in Osteotomy	p. 547
Lasers in Dentistry	p. 547
Index	p. 555
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