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In this paper, laser welding Ni to Al using pulsed wave (PW) and continuous wave (CW) lasers was investigated. Weld quality and strength were evaluated in terms of cross-section examination, intermetallic compounds formation, microhardness, shear test and 90-degree peel test. The results show that deep penetration welding Ni to Al causes high melting pool temperature and severe material mixing, which could result in dominant AlNi3 and AlNi intermetallics (IMCs) in the weld. These IMCs could significantly increase the hardness of the welding zone, but could also lead to the formation of defects, as well as reducing the ability to withstand the shear force and peel force applied to the weld. In comparison, using process optimization to maintain a shallow penetration or form a weld-braze joint, low melting pool temperature and minimum material mixing can be achieved. Hence, low-hardness Al3Ni IMCs are prevalent in the weld. This helps generate a defect-free dissimilar weld joint to withstand higher shear force and peel force. The findings show promising applications, such as the battery management system of electric vehicles, in which joining a Ni adaptor to an Al bus bar is required. [ABSTRACT FROM AUTHOR]

External humidification has been used as a flexible water management strategy for the proton exchange membrane fuel cell (PEMFC). To study the anode inlet relative humidity (ARH) effect on the performance of PEMFC, the anode inlet water content (AIWC) model is established, including condensation rates and water activity. A comparable analysis between the AIWC model, Fluent model and experiment is conducted at 60 °C operating temperature, four different anode relative humidities (25%, 50%, 75% and 100%), and 100% cathode relative humidity (CRH). The species distributions of water content and hydrogen concentration are presented and analyzed. The results show the relative error of the voltage results derived from the AIWC model has been reduced by 3.2% (the original is 4.6% in the Fluent model) especially at 240 mA·cm−2 for 50% ARH. An increase in hydrogen humidity can improve the PEMFC output at low ARH (25% and 50%). Meanwhile, at high ARH (100%), the excess water produced does not play a positive role. At 50% ARH, the water content and hydrogen distribution are more uniform all over the anode channels. [ABSTRACT FROM AUTHOR]

In this study, deposition of Tribaloy T800 on cobalt-based L605 substrate using micro-laser-aided additive manufacturing (micro-LAAM) was explored. The micro-LAAM process was studied to achieve sound integrity of the deposited layer. The microhardness and microstructure of the deposited Tribaloy T800 layer were investigated. The results showed that the developed micro-LAAM process can achieve single-layer crack-free deposition of Tribaloy T800 onto cobalt-based L605 without pre-heating of the substrate. Surface roughness of Ra 8 μm was obtained, indicating that micro-LAAM can significantly improve the surface quality. Very high microhardness in the range of 818 to 1000 Hv was achieved. Cellular grains with very fine dendritic microstructure and Laves phase were observed in the deposited Tribaloy T800, which contributed to the high hardness. With all the results obtained, it can be concluded that it is feasible to deposit Tribaloy T800 on L605 substrate with micro-LAAM to achieve sound integrity and high hardness. [ABSTRACT FROM AUTHOR]

Improving the surface roughness quality of 3D printed components, especially metallic ones, which are fabricated from the selective laser melting (SLM) method, has drawn enormous attention from the research community. It should be noted that various studies on this topic have reported that precise surface roughness results can be obtained with various techniques that are indeed not cost-effective. Differing itself from these studies, this manuscript investigates an economical solution for fabricating and surface treating SLM components. Specifically, the inspected specimens were printed with recycled 316L stainless steel powder and treated solely with two abrasive surface finishing methods. In the manuscript, two scanning strategies namely meander and stripes, and three types of surfaces were investigated. Subsequently, their 2D and 3D surface roughness results were elaborated. After the proposed herein abrasive treatment, 3D surface roughness arithmetical mean height of a surface (Sa) value of 0.9 µm can be achieved. [ABSTRACT FROM AUTHOR]

Optical laser head is a key component used to shape the laser beam and to deliver higher power laser irradiation onto workpieces for material processing. A focused laser beam size and optical intensity need to be controlled to avoid decreasing beam quality and loss of intensity in laser material processing. This paper reports the multiphysics modeling of an in-house developed laser head for laser-aided additive manufacturing (LAAM) applications. The design of computer experiments (DoCE) combined with the response surface model was used as an efficient design approach to optimize the optical performance of a high power LAAM head. A coupled structural-thermal-optical-performance (STOP) model was developed to evaluate the influence of thermal effects on the optical performance. A number of experiments with different laser powers, laser beam focal plane positions, and environmental settings were designed and simulated using the STOP model for sensitivity analysis. The response models of the optical performance were constructed using DoCE and regression analysis. Based on the response models, optimal design settings were predicted and validated with the simulations. The results show that the proposed design approach is effective in obtaining optimal solutions for optical performance of the laser head in LAAM. [ABSTRACT FROM AUTHOR]

Closed-loop control is desirable in direct energy deposition (DED) to stabilize the process and improve the fabrication quality. Most existing DED controllers require system identifications by experiments to obtain plant models or layer-dependent adaptive control rules, and such processes are cumbersome and time-consuming. This paper proposes a novel data-driven adaptive control strategy to adjust laser voltage with the melt pool size feedback. A multitasking controller architecture is developed to incorporate an autotuning unit that optimizes controller parameters based on the DED process data automatically. Experimental validations show improvements in the geometric accuracy and melt pool consistency of controlled samples. The main advantage of the proposed controller is that it can adapt to DED processes with different part shapes, materials, tool paths, and process parameters without tweaking. System identification is not required even when process conditions are changed, which reduces the controller implementation time and cost for end-users. [ABSTRACT FROM AUTHOR]

10.3390/app10207211 5 Yang J., Yao X., Cai Y., Bi G. Multiphysics Modeling, Sensitivity Analysis, and Optical Performance Optimization for Optical Laser Head in Additive Manufacturing. Laser-based additive manufacturing is an interdisciplinary research area in optoelectronics, mechanical engineering, materials science, control, topology design, numerical computing, and other fields. As a unique and powerful heat source, lasers are very important for the surface modification, re-manufacturing, and direct fabrication of 3D components. [Extracted from the article]

Additive manufacturing (AM) has become more prominent in leading industries. Recently, there have been intense efforts to achieve a fully functional 3D structural electronic device by integrating conductive structures into AM parts. Here, we introduce a simple approach to creating a conductive layer on a polymer AM part by CO2 laser processing. Scanning electron microscopy (SEM), transmission electron microscopy (TEM), and Raman spectroscopy were employed to analyze laser-induced modifications in surface morphology and surface chemistry. The results suggest that conductive porous graphene was obtained from the AM-produced carbon precursor after the CO2 laser scanning. At a laser power of 4.5 W, the lowest sheet resistance of 15.9 Ω/sq was obtained, indicating the excellent electrical conductivity of the laser-induced graphene (LIG). The conductive graphene on the AM parts could serve as an electrical interconnection and shows a potential for the manufacturing of electronics components. An interdigital electrode capacitor was written on the AM parts to demonstrate the capability of LIG. Cyclic voltammetry, galvanostatic charge-discharge, and cyclability testing demonstrated good electrochemical performance of the LIG capacitor. These findings may create opportunities for the integration of laser direct writing electronic and additive manufacturing. [ABSTRACT FROM AUTHOR]