Numerical research on effect of overlap ratio on thermal-stress behaviors of the high-speed laser cladding coating

High-speed laser cladding technology, a kind of surface technology to improve the wear-resistance and corrosion-resistance of mechanical parts, has the characterizations of fast scan speed, high powder utilization rate, and high cladding efficiency. However, its thermal-stress evolution process is very complex, which has a great influence on the residual stress and deformation. In the paper, the numerical models for the high-speed laser cladding coatings with overlap ratios of 10%,30%, and 50% are developed to investigate the influence rules of overlap ratio on the thermal-stress evolution, as well as the residual stresses and deformations. Results show that the heat accumulation can reheat and preheat the adjacent track coating and substrate, resulting in stress release of the previous track coating and decreased longitudinal stress peak of the next track coating. With the overlap ratio increasing, the heat accumulation and the corresponding maximum residual stress position tend to locate in the center of the cladding coating, where the coating has a high crack susceptibility. For a small overlap ratio of 10%, there are abrupt stress changes from tensile stress to compressive stress at the lap joint, due to insufficient input energy in the position. Increasing the overlap ratio can alleviate the abrupt stress change and reduce the residual deformation but increase the average residual stress and enlarge the hardening depth. This study reveals the mechanism of thermal-stress evolution, and provides a theoretical basis for improving the coating quality.

Effect of high-speed laser cladding on microstructure and corrosion resistance of CoCrFeNiMo_(0.2) high-entropy alloy

In order to study the corrosion resistance of high-speed laser cladding(HLC) coating while improving production efficiency,a CoCrFeNiMo_(0.2)high-entropy alloy(HEA) coating was prepared by HLC.The optimized parameters of HLC are laser power of 880 W,scanning speed of 18 m/min,overlapping ratio of 60%,and powder feed speed of 3 r/min.Then,the surface roughness,microstructure,phase composition,element distribution,and electrochemical properties in 3.5 wt% NaCl solution of the coatings were analyzed,respectively.The local surface roughness of the CoCrFeNiMo_(0.2)HEA coating was found to be 15.53 μm.A distinct metallurgical bond could be observed between the coating and the substrate.Compared to the conventional laser cladding(CLC),the results of electrochemical tests showed that CoCrFeNiMo_(0.2)HEA coating exhibited a significant passivation.The corrosion current density of 5.4411 × 10^(-6)A·cm^(-2) and the corrosion potential of-0.7445 V for the HLC coating were calculated by the Tafel extrapolation method.The CLC coating’s corrosion current density and corrosion potential are 2.7083×10^(-5)A·cm^(-2) and-0.9685 V,respectively.The HLC coating shows a superior corrosion resistance,crucially due to the uniform and fine grains.Under various complex and harsh working conditions,this method can be widely used in the field of repairing and remanufacturing of corro sion-proof workpiece s.

Microstructure,Properties and Crack Suppression Mechanism of High-speed Steel Fabricated by Selective Laser Melting at Different Process Parameters

To enrich material types applied to additive manufacturing and enlarge application scope of additive manufacturing in conformal cooling tools,M2 high-speed steel specimens were fabricated by selective laser melting(SLM).Effects of SLM parameters on the microstructure and mechanical properties of M2 high-speed steel were investigated.The results showed that substrate temperature and energy density had significant influence on the densification process of materials and defects control.Models to evaluate the effect of substrate temperature and energy density on hardness were studied.The optimized process parameters,laser power,scan speed,scan distance,and substrate temperature,for fabricated M2 are 220 W,960 mm/s,0.06 mm,and 200℃,respectively.Based on this,the hardness and tensile strength reached 60 HRC and 1000 MPa,respectively.Interlaminar crack formation and suppression mechanism and the relationship between temperature gradient and thermal stress were illustrated.The inhibition effect of substrate temperature on the cracks generated by residual stresses was also explained.AM showed great application potential in the field of special conformal cooling cutting tool preparation.

Surface Integrity of Inconel 738LC Parts Manufactured by Selective Laser Melting Followed by High-speed Milling

This study is concerned with the surface integrity of Inconel 738LC parts manufactured by selective laser melting(SLM)followed by high-speed milling(HSM).In the investigation process of surface integrity,the study employs ultradepth three-dimensional microscopy,laser scanning confocal microscopy,scanning electron microscopy,electron backscatter diffractometry,and energy dispersive spectroscopy to characterize the evolution of material microstructure,work hardening,residual stress coupling,and anisotropic effect of the building direction on surface integrity of the samples.The results show that SLM/HSM hybrid manufacturing can be an effective method to obtain better surface quality with a thinner machining metamorphic layer.High-speed machining is adopted to reduce cutting force and suppress machining heat,which is an effective way to produce better surface mechanical properties during the SLM/HSM hybrid manufacturing process.In general,high-speed milling of the SLM-built Inconel 738LC samples offers better surface integrity,compared to simplex additive manufacturing or casting.

Algorithm implementation of high-speed laser g yro signal demodulation filter

Based on the characteristics of field-programmable gate array(FPGA) such as multi-task,high-speed,parallelity,etc,a filtering algorithm is presented to filter the output signal of laser gyr o with high-speed and high accuracy.The filter is composed of basic logic cell s,multipliers an d memory inside FPGA.By using an multiplication decomposition method and design ing reliable time-sequence,the filter is realized,which is easy to be transpl anted and of low cost.Furthermore,all the signal demodulation algorithms of t he laser gyr oscope can be integrated in only one FPGA,which reduces the cost and complexity of the system.

Formation, microstructure and mechanical properties of double-sided laser beam welded Ti-6Al-4V T-joint

The T-joints of Ti?6Al?4V alloy were manufactured by double-sided synchronized laser beam welding with the homologous filler wire. The formation, microstructure and mechanical properties of welded joints as well as the correlations of each other were investigated. The results indicate that the quality of weld seams is good without defects such as discontinuity, beading, visible cracks or porosity, which is linked to the steady molten pool behavior and droplet transition. The morphologies of the heat affected zone (HAZ) located on the skin and stringer are disparate. The microstructure of the HAZ and fusion zone (FZ) is mainly comprised of acicular martensiticα′ phases. The microhardness of the HAZ and FZ is higher than that of the base metal (BM) and reaches a maximum value at the HAZ near FZ on the stringer. The tensile specimens along the skin and stringer fractured at the BM with ductile fracture surfaces.

Laser-pulsed MIG hybrid welding technology of A6N01S aluminum alloy

Welding research of A6N01S-T5 aluminum alloy profile for high-speed train was done by using laser-MIG hybrid welding and MIG welding individually. And the weld appearance,welding distortion,mechanical properties of the joints and microstructures were analyzed. The test results demonstrated that high-efficient welding for the profile can be achieved by using laser-MIG hybrid welding,the speed of which can be over 3. 0 m/min. The processing had a good gap bridging ability,even if the gap of the butt joint was up to 2. 0 mm,a good weld appearance can also be got. While the hybrid welding speed was greater than 2. 5 m/min,the welding distortion of the laser-tandem MIG hybrid joints was just about 33% of that of the MIG joints,but the welding efficiency was over 3 times of MIG welding. And tensile strength of the hybrid joints was 85% of that of A6N01S-T5 base metal,9% higher than that of the MIG joints. Fatigue properties was tested individually with pulsed tensile fatigue method in the condition of 1 × 10~7 lifetime. The test results demonstrated that the fatigue strength of the joints was a little lower than that of base material,which could be up to 115 MPa. But the fatigue strength of hybrid welding joints was 107. 5 MPa,which was 23% higher than 87 MPa of MIG welding joints.

Analysis of Laser-Induced Plume During Disk Laser Welding at Different Speeds

During high power disk laser welding, the high-speed photography was used to measure the dynamic images of the laser-induced plume at different laser welding speeds. Various plume features （area, height and brightness） were extracted from the images by the color space clustering algorithm. Combined with observation on the surface and the cross sections of welding samples, the effect of welding speed on welding stability was analyzed. From the experimental results, it was found that these features of plume could reflect the welding state. Thus changes of the plume features corresponded to different welding speeds, which was helpful for monitoring the laser welding stability.

Molten pool and temperature field in CO_2 laser welding

Two measuring methods, high-speed camera and optical monitoring system, were used to study processes of laser welding. Molten pool, cooling time and temperature field were analyzed based on real measured images and optical signal data. The results show that the width of molten pool is almost equal to the width of weld, and length is about 7. 8 mm. The solidification time is about 0. 5 s and the temperature gradient is great, so HAZ is very small. The method and results will be of benefit to build the relationship between welding parameters and microstructure.

3D particle tracking velocimetry for the determination of temporally resolved particle trajectories within laser powder bed fusion of metals

Within this work,we present a system for the measurement of the three-dimensional(3D)trajectories of spatters and entrained particles during laser powder bed fusion(L-PBF)of metals.It is comprised of two ultrahigh-speed cameras and a reconstruction task specific processing reconstruction algorithm.The system enables an automated determination of 3D measures from the trajectories of a large number of tracked particles.Ambiguity evolving from an underdetermined geometrical situation induced by a two-camera setup is resolved within the tracking using a priori knowledge of L-PBF of metals.All processing steps were optimized to run on a graphics processing unit to allow the processing of large amounts of data within an appropriate time frame.The overall approach was validated by a comparison of the measurement results to synthetic images with a known 3D ground truth.

Pulse-burst laser-based 10kHz Thomson scattering measurements

Thomson scattering (TS), as a popular and reliable diagnostic technique, has successfully measured electron temperatures and electron number densities of plasmas for many years. However, conventional TS techniques using Nd:YAG lasers operate only at tens of hertz. Here, we present the development of a high-repetition-rate TS instrument based on a high-speed, pulse-burst laser system to greatly increase the temporal resolution of measurements. Successful instrument prototype testing was carried out by collecting TS light from laboratory helium and argon plasmas at 10 kHz. Calibration of the instrument detection sensitivity using nitrogen/ oxygen rotational Raman scattering signal is also presented. Quantitative electron number densities and electron temperatures of the plasma were acquired at 10 kHz, for stable plasma discharges as, respectively,~0.9 eV and ~5.37×10^21 m^-3 for the argon plasma, and ~1 eV and ~6.5×10^21 m^-3 for the helium plasma.

High-Speed Mach-Zehnder-OTDR Distributed Optical Fiber Vibration Sensor Using Medium-Coherence Laser

This article presents a high-speed distributed vibration sensing based on Mach-Zehnder-OTDR （optical time-domain reflectometry）. Ultra-weak fiber Bragg gratings （UWFBG）, whose backward light intensity is 2-4 orders of magnitude higher than that of Rayleigh scattering, are used as the reflection markers. A medium-coherence laser can substitute conventional narrow bandwidth source to achieve an excellent performance of distributed vibration sensing since our unbalanced interferometer matches the interval of UWFBGs. The 3 m of spatial resolution of coherent detection and multiple simultaneous vibration sources locating can be realized based on OTDR. The enhanced signal to noise ratio （SNR） enables fast detection of distributed vibration without averaging. The fastest vibration of 25 kHz and the slowest vibration of 10Hz can be detected with our system successfully, and the linearity is 0.9896 with a maximum deviation of 3.46nε.

Relative intensity noise in high-speed hybrid square-rectangular lasers

Relative intensity noise(RIN) and high-speed modulation characteristics are investigated for an Al Ga In As/In P hybrid square-rectangular laser(HSRL) with square side length, rectangular length, and width of 15,300, and 2 μm, respectively. Single-mode operation with side-mode suppression larger than 40 dB has been realized for the HSRL over wide variation of the injection currents. In addition, the HSRL exhibits a 3 dB modulation bandwidth of 15.5 GHz, and an RIN nearly approaches standard quantum shot-noise limit 2 hv∕P=-164 dB∕Hz at high bias currents due to the strong mode selection of the square microcavity. With the increase of the DC bias current of the Fabry–Perot section, significantly enhanced modulation bandwidth and decreased RIN are observed.Furthermore, intrinsic parameters such as resonance frequency, damping factor, and modified Schawlow–Townes linewidth are extracted from the noise spectra.

High-speed and high-performance polarization-based quantum key distribution system without side channel effects caused by multiple lasers

Side channel effects such as temporal disparity and intensity fluctuation of the photon pulses caused by random bit generation with multiple laser diodes in high-speed polarization-based BB84 quantum key distribution(QKD) systems can be eliminated by increasing the DC bias current condition. However, background photons caused by the spontaneous emission process under high DC bias current degrade the performance of QKD systems. In this study, we investigated the effects of spontaneously emitted photons on the system performance in a high-speed QKD system at a clock rate of 400 MHz. Also, we show further improvements in the system performance without side channel effects by utilizing the temporal filtering technique with real-time fieldprogrammable gate array signal processing.

Uniformly Dispersed Carbide Reinforcements in the Medium-Entropy High-Speed Steel Coatings by Wide-Band Laser Cladding

A medium-entropy high-speed steel(ME-HSS)coating with the 76 at.%of Fe and multiple alloying elements was prepared by the wide-band laser cladding.Compared with the commercial W6 Mo5 Cr4 V2(M2)HSS coating which contains a large number of network lamellar M2 C-type carbides along the grain boundaries,the presented ME-HSS coating has a high quantity of fi ner and more uniformly dispersed M C-type carbides;on the other hand,the coating has less retained austenite and much lower brittleness as well as similar secondary hardening eff ect and tempering hardness.

Serrated chip characteristics and formation mechanism in high-speed machining of selective laser melted Ti6Al4V alloys

Serrated chips,consisting of extremely uneven plastic deformation,are a prominent feature of high-speed machining of difficultto-machine materials.This paper focuses on the evolution of chip form,chip morphology features(chip free surface,tool-chip contact surface,and chip edge),and chip segment parameters in subsequent high-speed(vc=50 and 150 m min-1)machining of selective laser melted(SLMed)Ti6Al4V alloys,which are significantly different from conventional Ti6Al4V alloy in microstructure,mechanical properties and machinability.The effect of laser beam scanning schemes(0°,67.5°,and 90°),machined surfaces(top and front),and cutting speeds on serrated chip characteristics of SLMed Ti6Al4Valloys was investigated.Based on the Johnson-Cook constitutive model of SLMed Ti6Al4Valloys,an orthogonal cutting model was developed to better understand the effect of physical-mechanical properties on the shear localization,which dominates the formation mechanism of serrated chips in post-machining of SLMed Ti6Al4V alloy.The results showed that the critical cutting speed(CCS)for chip serration of SLMed Ti6Al4V alloy is lower than that for serrated chips of conventional Ti6Al4V alloy,and the serrated profile of SLMed Ti6Al4V chips was more regular and pronounced.Besides,due to anisotropic microstructure and mechanical properties of SLMed Ti6Al4Valloys,the serration degree of chips produced on the top surfaces of SLMed Ti6Al4Valloys is more prominent than that of chips generated on the front surfaces.In addition,because of the poor deformation coordination and high plastic flow stresses of needle-like martensiteα′,the plastic flow and grain distortion in the adiabatic shear band(ASB)of SLMed Ti6Al4V chips are significantly smaller than those in the ASB of conventional Ti6Al4V with equiaxed grains.

Silicon photonic transceivers for application in data centers

Global data traffic is growing rapidly,and the demand for optoelectronic transceivers applied in data centers(DCs)is also increasing correspondingly.In this review,we first briefly introduce the development of optoelectronics transceivers in DCs,as well as the advantages of silicon photonic chips fabricated by complementary metal oxide semiconductor process.We also summarize the research on the main components in silicon photonic transceivers.In particular,quantum dot lasers have shown great potential as light sources for silicon photonic integration—whether to adopt bonding method or monolithic integration—thanks to their unique advantages over the conventional quantum-well counterparts.Some of the solutions for highspeed optical interconnection in DCs are then discussed.Among them,wavelength division multiplexing and four-level pulseamplitude modulation have been widely studied and applied.At present,the application of coherent optical communication technology has moved from the backbone network,to the metro network,and then to DCs.

Development of readout electronics for bunch arrival-time monitor system at SXFEL

A bunch arrival-time monitor(BAM) system,based on electro-optical intensity modulation scheme, is under study at Shanghai Soft X-ray Free Electron Laser.The aim of the study is to achieve high-precision time measurement for minimizing bunch fluctuations. A readout electronics is developed to fulfill the requirements of the BAM system. The readout electronics is mainly composed of a signal conditioning circuit, field-programmable gate array(FPGA), mezzanine card(FMC150), and powerful FPGA carrier board. The signal conditioning circuit converts the laser pulses into electrical pulse signals using a photodiode. Thereafter, it performs splitting and low-noise amplification to achieve the best voltage sampling performance of the dual-channel analog-to-digital converter(ADC) in FMC150. The FMC150 ADC daughter card includes a 14-bit 250 Msps dual-channel high-speed ADC,a clock configuration, and a management module. The powerful FPGA carrier board is a commercial high-performance Xilinx Kintex-7 FPGA evaluation board. To achieve clock and data alignment for ADC data capture at a high sampling rate, we used ISERDES, IDELAY, and dedicated carry-in resources in the Kintex-7 FPGA. This paper presents a detailed development of the readout electronics in the BAM system and its performance.

Wavelength-swept fiber laser based on bidirectional used linear chirped fiber Bragg grating

A wavelength-swept fiber laser is proposed and successfully demonstrated based on a bidirectional used linear chirped fiber Bragg grating(LC-FBG). The wavelength-swept operation principle is based on intracavity pulse stretching and compression. The LC-FBG can introduce equivalent positive and negative dispersion simultaneously, which enables a perfect dispersion matching to obtain wide-bandwidth mode-locking. Experimental results demonstrate a wavelength-swept fiber laser that exhibits a sweep rate of about 5.4 MHz over a 2.1 nm range at a center wavelength of 1550 nm. It has the advantages of simple configuration and perfect dispersion matching in the laser cavity.

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

Energy field-assisted machining technology has the potential to overcome the limitations of machining difficult-to-machine metal materials,such as poor machinability,low cutting efficiency,and high energy consumption.High-speed dry milling has emerged as a typical green processing technology due to its high processing efficiency and avoidance of cutting fluids.However,the lack of necessary cooling and lubrication in high-speed dry milling makes it difficult to meet the continuous milling requirements for difficult-to-machine metal materials.The introduction of advanced energy-field-assisted green processing technology can improve the machinability of such metallic materials and achieve efficient precision manufacturing,making it a focus of academic and industrial research.In this review,the characteristics and limitations of high-speed dry milling of difficult-to-machine metal materials,including titanium alloys,nickel-based alloys,and high-strength steel,are systematically explored.The laser energy field,ultrasonic energy field,and cryogenic minimum quantity lubrication energy fields are introduced.By analyzing the effects of changing the energy field and cutting parameters on tool wear,chip morphology,cutting force,temperature,and surface quality of the workpiece during milling,the superiority of energy-field-assisted milling of difficult-to-machine metal materials is demonstrated.Finally,the shortcomings and technical challenges of energy-field-assisted milling are summarized in detail,providing feasible ideas for realizing multi-energy field collaborative green machining of difficult-to-machine metal materials in the future.