Laser in Manufacturing

by Davim, J. Paulo

• ISBN13: 9781848213692
• ISBN10: 1848213697
• Edition: 1st
• Format: Hardcover
• Copyright: 2012-04-09
• Publisher: Wiley-ISTE

Summary

LASER material processing represents a great number of methods which are growing rapidly in current and different industrial applications as new alternatives to traditional manufacturing processes. Nowadays, LASER in manufacturing is an emerging area with a wide variety of applications, for example, in electronics, moulds and dies and biomedical applications. This book addresses the fundamentals and recent reseach advances on LASER manufacturing.

Author Biography

J. Paulo Davim is Aggregate Professor in the Department of Mechanical Engineering at the University of Aveiro, Portugal and is Head of MACTRIB (Machining and Tribology Research Group). His main research interests include manufacturing, materials and mechanical engineering.

Table of Contents

Preface	p. xi
Laser Rapid Manufacturing: Technology, Applications, Modeling and Future Prospects	p. 1
Introduction	p. 1
Laser rapid manufacturing	p. 2
Laser rapid manufacturing system	p. 4
High power laser system	p. 4
Material feeding system	p. 5
CNC workstation	p. 13
Various laser rapid manufacturing systems	p. 13
Relevant processing parameters	p. 16
Typical applications of LRM	p. 24
Colmonoy-6 bushes	p. 24
Solid and porous structures of Inconel-625	p. 27
Cemented carbide components	p. 33
Erosion wear resistant surfaces	p. 37
LRM process modeling	p. 41
LRM process control	p. 51
Measurement of melt-pool temperature	p. 53
Measurement of track geometry	p. 55
LRM process controllers	p. 56
Future prospects	p. 57
Conclusion	p. 59
Acknowledgments	p. 60
Bibliography	p. 60
Lasers in Metal Forming Applications	p. 69
Introduction	p. 69
Laser	p. 70
Metal forming - introduction	p. 72
Laser beam forming	p. 73
Principles of LBF	p. 74
Parameters influencing the LBF process	p. 75
LBF mechanisms	p. 84
Temperature gradient mechanism (TGM)	p. 86
Buckling mechanism	p. 88
Point mechanism	p. 89
Shortening or upsetting mechanism	p. 90
Advantages and disadvantages of LBF	p. 91
LBF of a steel plate	p. 92
Introduction	p. 92
Material	p. 92
Laser system	p. 93
Experimental LBF setup	p. 94
Design of experiments	p. 95
Taguchi design	p. 96
Effect of LBF factors on the resulting curvature	p. 99
Sample characterization	p. 100
Optical microscopy	p. 100
Microhardness	p. 102
Tensile test	p. 102
Conclusion	p. 104
Bibliography	p. 104
Laser Forming of Metal Foams	p. 109
Introduction	p. 109
Scientific background	p. 110
Aluminum foam sandwich panels	p. 110
Open-cell aluminum foams	p. 111
Laser forming	p. 113
Materials and experimental methods	p. 113
Materials	p. 115
Laser bending tests	p. 115
Material analyses	p. 117
Experimental results and discussion	p. 117
Open-cell foams	p. 117
Closed-cell foams (AFS panels)	p. 120
The comparison	p. 121
Obtaining high bending angles	p. 123
Mechanical testing	p. 124
Micro-structural analysis	p. 125
Numerical modeling	p. 127
The finite element model	p. 127
Laser processing simulation	p. 127
Compression test simulation	p. 129
Numerical results	p. 131
Conclusions	p. 134
Bibliography	p. 135
Mathematical Modeling of Laser Drilling	p. 139
Introduction	p. 139
Solid heating	p. 141
Melting	p. 145
Vaporization	p. 151
Mathematical model of laser percussion drilling incorporating the effects of the exothermic reaction	p. 156
Modeling the pulse-on heating process	p. 156
Solidification during pulse-off	p. 164
Experimental procedures for model verification	p. 167
Results and discussion	p. 168
Conclusion	p. 173
Bibliography	p. 173
Laser Cutting a Small Diameter Hole: Thermal Stress Analysis	p. 179
Introduction	p. 179
Modeling heating and thermal stress	p. 181
Heating analysis	p. 181
Thermal stress analysis	p. 183
Numerical simulation	p. 184
Experimental	p. 185
Results and discussion	p. 186
Conclusion	p. 201
Acknowledgements	p. 201
Bibliography	p. 201
Modeling and Simulation of Laser Welding	p. 203
Introduction	p. 204
Process mechanisms	p. 204
Operating parameter characteristics	p. 206
Types	p. 207
Gas laser	p. 208
Solid state laser	p. 208
Diode laser	p. 209
Fiber lasers	p. 209
Material considerations	p. 209
Applications of laser welding	p. 211
Strengths and limitations of laser welding	p. 212
Developments and advances in laser welding processes	p. 213
Modeling and analysis of the laser welding process	p. 214
Design of experiments	p. 214
Box-Behnken design	p. 215
Artificial neural network	p. 216
Finite element analysis	p. 219
A case study	p. 220
Experimental setup	p. 220
Mathematical modeling of built joint	p. 222
Process parameters interaction effect on the butt joint profile	p. 227
ANN modeling	p. 230
Finite element analysis	p. 234
Comparison of statistical analysis, the finite element method and an ANN	p. 241
Conclusion	p. 243
Acknowledgment	p. 244
Bibliography	p. 244
Lasers in Surface Engineering	p. 247
Introduction	p. 248
Characteristics of laser radiation	p. 248
Monochromaticity	p. 248
Directionality and divergence	p. 249
Coherence	p. 249
Advantages of laser devices	p. 249
Laser surface cladding	p. 250
Introduction	p. 250
Process description	p. 251
Process parameters	p. 252
Laser surface cladding by powder injection	p. 253
Types of powder injection techniques	p. 255
Energetic study of the cladding process	p. 257
Energy losses due to reflection off the surface of the cladding area	p. 260
Energy losses due to radiation	p. 261
Energy losses due to convection	p. 262
Energy used in creating and bonding the coating	p. 263
Control parameters of laser surface cladding	p. 264
Widely used materials and alloys	p. 266
Laser surface treatments	p. 266
Introduction	p. 266
Laser hardening	p. 267
Laser surface melting	p. 267
Laser surface texturing	p. 267
Laser surface texturing techniques	p. 272
Melting	p. 272
Vaporization	p. 274
Melting and vaporization:	p. 274
Melting and gas injection	p. 276
Process parameters	p. 279
Characterization of laser surface texturing	p. 285
Geometry	p. 285
Density	p. 286
Bibliography	p. 286
List of Authors	p. 293
Index	p. 297
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