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The present book covers the application technology of lasers, focusing more on the vast range of processes than on individual applications, in order to motivate and enable future innovations. The physical basics are presented in the first half of the book. The following examination of application categories and their processes is documented by experts from their practical points of view but always refers back to the underlying physical principles. In this way, readers are free to choose their own individual level of depth in understanding this globally relevant field of innovation.
The Laser world consists basically of two areas, which are necessary and in many cases also sufficient for effective innovation: The right laser for the right application. For the individual application that means the determination of optimized process parameters in terms of laser power, peak power/ intensity, focus geometry and dimension, pulse length, pulse repetition rate and wavelength to name only the six most important ones. Once these parameters are identified, the corresponding Laser has to be selected on the basis of commercial availability. Obviously there is no such thing than "One Laser for all". The situation is rather comparable with electrical power, were depending on the demand of the application in terms of voltage, current and time corresponding power supplies need to be tailored, however, with the difference that in the case of the Laser the variety of parameters is even higher, thus the technology is more complex but on the other hand much more flexible in terms optimizing the source to the application. As a consequence it is suggested to generate two volumes on Lasers and Applications named "Tailored Light".
High precision, high quality, and high throughput of ultrashort pulse laser ablation of bulk material are the most demanded properties that are required to let this process technology compete with other micro-machining techniques. Previous attempts to increase volumetric ablation rates of ultrashort pulse laser processes were based on the increase of fluence or pulse repetition rates. They run into limitations mainly set by the occurrence of bumpy surfaces due to overheating of bulk material. In this work, the potential of laser beam shaping for the enhancement of ablation rates is studied systematically for the first time. The question regarding the physically shortest possible process time for ablation of 2.5D-structures by means of an ultrashort pulse laser is answered using a heat conduction model, which is extended by the ability to consider spatially shaped beams. The strategy of laser beam stamping is implemented in a novel optical setup and proven both theoretically and experimentally to have a great potential for increasing ablation rates.
In this dissertation a new process chain for the Additive Manufacturing of Mechatronic Integrated Devices (AMMID) is described, which provides a new way to manufacture 3-dimensional electronic devices based on the selective laser sintering (SLS) process using laser direct structuring (LDS) and metallization. The AMMID process chain meets the rising demand for highly functionalized parts, increasing individualization and shortening development cycles for electronic products. The development for this process chain is based on an extensive literature review that indicates that an SLS-based process chain has great potential to produce 3-dimensional electronic devices with properties and with the future perspective of being suitable for an individualized mass production. The biggest, initial, technical hurdle is an unstable SLS process using a conventional LDS additive. The compound of SLS material and LDS additive was analyzed with DSC, which shows that the additive changes the melting behavior of the polymer by reducing the sintering window. A fine metal powder as an alternative additive affects the sintering window less and enables a stable process. To choose a suitable particle size and content for the metal powder an analytical material model is provided, that predicts the additive particle distribution within the material. This material model deepens the understanding of the activation mechanism during laser activation, provides hands-on information for powder preparation and it is applied for the design of the experiment for the development of the process chain with the new material. Preliminary experiments are conducted along with the insights of the material model, which prove that redeposition is the main activation mechanism during laser activation with fine metal powders. Based on this, the process chain is developed, starting with a determination of a suitable additive content. A suitable material composition of a PA12 powder containing 2 wt.% of a copper powder with a mean particle diameter of 3.5 μm was identified. With regard to the laser activation, working laser parameters are developed (working parameter set feasible for all used post-process treatments: PRF = 1 kHz, dh = 25 μm, vs = 25 mm/s, tl = 20ns and P = 1.07 W). In this parameter development it is shown, that only closely located laser spots, enabling interaction of the laser pulses, are capable of activating the surface, while single laser pulses under applied conditions are not. By adding a post-process treatment as additional process step into the process chain, the quality of metallization and the size of design features could be improved. Chemical smoothing resulted in a complete reduction of unwanted metallization on non-activated surfaces. Conductor tracks with the minimal width of 300 μm could be realized. The process chain could be applied to demonstrator parts such as a drone housing and a PSU panel of an aircraft. Thus, this dissertation has raised the technology readiness level (TRL) from TRL2 to TRL6. Finally, an economic consideration provides insights on the cost structure of parts produced with the AMMID process. A comparison of AMMID and injection molding shows economic viability for small lot sizes, 400 parts in case of the drone housing and 150 parts in case of the PSU panel. Finally, the analysis of the cost structure gives advice which future developments in the process chain have the greatest effect on costs and provides prioritization.
Structured singular light is an ubiquitous phenomenon. It is not only created when light refracts at a water surface but can also be found in the blue daytime sky. Such light fields include a spatially varying amplitude, phase, or polarization, enabling the occurrence of optical singularities. As structurally stable units of the light field, these singularities are particularly interesting since they determine its topology. In this excellent book, the author presents a pioneering study of structured singular light, thereby contributing many original approaches. Especially in the field of polarization and its rich number of different types of singularities the book defines and drives a completely new field. The work demonstrates how to control complex polarization singularity networks and their propagation. Additionally, the author pioneers tightly focusing vectorial beams, also developing an urgently needed detection scheme for three-dimensional nanoscale polarization structures. She also studies classical spatial entanglement using structured light, introducing entanglement beating and paraxial spin-orbit-coupling. The book is hallmarked by its comprehensive and thorough way of describing a plethora of different approaches to structure light by amplitude, phase and polarization, as well as the important role of optical singularities.
This book delves deeply into the real-world technologies behind the ‘directed energy weapons’ that many believe exist only within the confines of science fiction. On the contrary, directed energy weapons such as high energy lasers are very real, and this book provides a crash course in all the physical and mathematical concepts that make these weapons a reality. Written to serve both scientists researching the physical phenomena of laser effects, as well as engineers focusing on practical applications, the author provides worked examples demonstrating issues such as how to solve for heat diffusion equation for different boundary and initial conditions. Several sections are devoted to reviewing and dealing with solutions of diffusion equations utilizing the aid of the integral transform techniques. Ultimately this book examines the state-of-the-art in currently available high energy laser technologies, and suggests future directions for accelerating practical applications in the field.“br>/div
This book reports on topics at the interface between material processing, product and process optimization. It covers new developments and challenges in welding, brazing, cutting and coating, casting and molding, additive manufacturing, simulation and optimization techniques, as well as functional and structural materials and composites. Gathering authoritative contributions on the latest research and applications, presented at the International Joint Conference on Enhanced Material and Part Optimization and Process Intensification, EMPOrIA 2020, organized by SFB1120 Aachen, SFB814 Erlangen and CCE Darmstadt, on May 19–20, 2020, in Aachen, this book provides academics, students, and professionals with a timely snapshot of the main research trends, and extensive information on cutting-edge methods and technologies in materials, manufacturing and process engineering.
Ultra-short pulse laser processing of ultra-hard materials requires an accurate and agile experimental and analytical investigation to determine an efficient choice of parameters and settings to optimize ablation. Therefore, this work presents a quality-oriented experimental approach and an analytical approach for the modeling and validation of multi-pulse picosecond laser beam ablation on cemented tungsten carbide. This work starts with a review of literature and state-of-the-art theories of four relevant areas for this research: picosecond lasers, laser beam ablation process, cemented tungsten carbide (WC) and quality-oriented tools. Subsequently, a concept for an efficient material laser beam ablation with a picosecond laser was introduced. Furthermore, two approaches for the investigation are presented from an experimental and analytical perspective, respectively. The first approach introduced a methodology for the identification of influential parameters. It executes a quality-oriented methodology based on the SWOT analysis, cause-and-effect diagram and the variable search methodology. The conclusion of the methodology gave the interaction of pulse repetition rate and scanner speed in the form of pulse overlap and track overlap PO/TO as the most influential parameter in the maximization of the ablation rate. The second most influential factors resulted laser beam power and burst-mode. The second approach, description of the model, executes a theoretical analysis of the picosecond laser beam ablation of cemented WC by the application of the Beer-Lambert law and multi-pulse ablation modeling. The unavailable material properties were obtained by experimental investigations, like in the cases of the incubation factor and the reflectivity factor. Threshold fluence for cemented WC was determined by the application of the heat transfer theory and input power intensity was adapted to a Gaussian beam profile. At the end of the approach, power density visualizations of a picosecond laser pulse under the five available pulse repetition rates were modeled and validated. The findings from the adaptation of the Beer-Lambert law acted as basis for development of the multi-pulse laser ablation model for both single-pulse mode and burst-mode, respectively. Based on the definition of the number of pulses N irradiating the same area, the corresponding threshold fluence for N, the input fluence and incubation factor, ablation depth was modeled and experimentally validated. Finally, results and conclusions of both approaches were discussed and a framework for an efficient laser beam ablation was presented. Recommendations for further actions on research and industry were introduced at the end of the work.