Parametric study of pulsed nanosecond laser interaction with carbon-nanotube composite bipolar plate for PEMFCs.

A laser processing technique is proposed for the processing of a 2.5 mm thick carbon nanotube (CNT) composite bipolar plate for proton exchange membrane fuel cells (PEMFCs). This study aims to understand laser interaction with the CNT composite plate experimentally using a pulsed nanosecond laser. Penetration depth, top width, spatter width, and overall physical morphologies are studied. Scanning electron microscope (SEM) and 3D Scanning Confocal Microscope were used for observation and measurements. Based on that, a parametric investigation is conducted and reported systematically. Most importantly, the pulse repetition rate presents a unique nature of interaction that resulted in a critical repetition rate distinguishing three operational regimes. The physical and chemical properties of the regimes are further analyzed by Vickers microhardness testing and energy dispersive X-ray (EDX) analyses performed on the surface and cross-section of each specimen. The results reveal that the pulse repetition rate introduces changes in mechanical properties and chemical compositions in the vicinity of the processed region. In conclusion, lower pulse repetition should be favored for less impact on mechanical properties, chemical composition, and morphological aspects.

An experimental investigation of laser scabbling on cement-based materials using nanosecond fiber laser.

In this study, the influence of a pulsed fiber laser of 250 W power with a spot size of 40 µm was successfully analyzed during scabbling of six types of cement mortar and three types of ultra-high-performance concrete (UHPC). Confocal microscopy on the surface of the scabbled samples elucidated the formation of three distinct zones: glassy layer (GL), partially melted zone (PMZ), and heat-affected zone (HAZ) with unique morphological appearances. The glassy layer exhibited bubble formation, whereas cracks were spotted alongside the scabbled area. The difference in scabbling depth between the beginning and end of the process was revealed by using 3D topography images. Moreover, the development of pores and the changes in the microstructure of each zone were observed by using scanning electron microscopy (SEM). Further energy dispersive X-ray (EDX) analysis also revealed significant changes in the percentage of silicon and calcium inside the glassy layer and non-processed zone (NPZ).

The interaction of high-power fiber laser irradiation with intrusive rocks.

Laser cutting of intrusive rocks, including granite, gabbro, and diorite, is carried out in order to assess the cut characteristics through geometrical measurements, such as kerf width, melting width, and penetration depth. The absorption rate for each specimen at the wavelength of 1064 nm is measured using a spectrophotometer. A multimode fiber laser is used in this study with the power of 9 kW and different cutting speeds. Furthermore, nitrogen gas at 13 bar is applied as the assistant gas in order to remove the melted material effectively. As a result of the experiment, the relationship between the cutting speed and geometrical measurements is investigated. Furthermore, variations of penetration depth are performed in accordance with the number of laser cuts. In addition, through energy dispersive X-ray (EDX) element mapping, minerals that comprise the rocks are classified and characterized. Subsequently, the changes in the microstructure and chemical composition of each specimen, before and after laser cutting, are compared using scanning electron microscope (SEM) and EDX analyses. Experimental results demonstrate that the cutting characteristics vary, depending on the types of minerals that make up the rock. Based on a series of tests, it is identified that volume energy of more than 3.06E + 13 [Formula: see text] is required to fully cut intrusive rocks that have a thickness of 25 mm.

Effect of Au-Coating on the Laser Spot Cutting on Spring Contact Probe (SCP) for Semi-Conductor Inspection.

Spring contact probes (SCPs) are used to make contact with various test points on printed circuit boards (PCBs), wire harnesses, and connectors. Moreover, they can consist of the test interface between the PCBs and the semiconductor devices. For mass production of SCPs, ultra-small precision components have been manufactured by conventional cutting methods. However, these cutting methods adversely affect the performance of components due to tool wear and extreme shear stress at the contact point. To solve this problem, laser spot cutting is applied to Au-coated SCP specimens as an alternative technique. A 20 W nano-second pulsed Ytterbium fiber laser is used, and the experimental variables are different laser parameters including the pulse duration and repetition rate. After the spot cutting experiments, the heat-affected zone (HAZ) and material removal zone (MRZ) formed by different total irradiated energy (Etotal) was observed by using a scanning electron microscope (SEM). Then, the size of HAZ, top and bottom parts of MRZ, and roundness were measured. Furthermore, the change rate of HAZ and MRZ on Au-coated and non-coated specimens was analyzed with regard to different pulse durations. Based on these results, the effect of Au-coating on the SCP was evaluated through the comparison with the non-coated specimen. Consequently, in the Au-coated specimen, hole penetration was observed at a low pulse duration and low total energy due to the higher thermal conductivity of Au. From this study, the applicability of laser spot cutting to Au-coated SCP is investigated.

A Comparative Study on the Wettability of Unstructured and Structured LiFePO4 with Nanosecond Pulsed Fiber Laser.

The wettability of electrodes increases the power and energy densities of the cells of lithium-ion batteries, which is vital to improving their electrochemical performance. Numerous studies in the past have attempted to explain the effect of electrolyte and calendering on wettability. In this work, the wettability behavior of structured and unstructured LiFePO4 electrodes was studied. Firstly, the wettability morphology of the structured electrode was analyzed, and the electrode geometry was quantified in terms of ablation top and bottom width, ablation depth, and aspect ratio. From the result of the geometry analysis, the minimum measured values of aspect ratio and ablation depth were used as structured electrodes. Laser structuring with pitch distances of 112 µm, 224 µm, and 448 µm was applied. Secondly, the wettability of the electrodes was measured mainly by total wetting time and electrolyte spreading area. This study demonstrates that the laser-based structuring of the electrode increases the electrochemically active surface area of the electrode. The electrode structured with 112 µm pitch distance exhibited the fastest wetting at a time of 13.5 s. However, the unstructured electrode exhibited full wetting at a time of 84 s.

An Experimental Investigation on the Cutting Quality of Three Different Rock Specimens Using High Power Multimode Fiber Laser.

The laser cutting of rock has been popular recently because of its advantages over traditional rock cutting methods. Several types of research were performed to replace traditional rock cutting techniques with laser cutting. The purpose of this experiment is to observe cutting quality for intrusive igneous rocks using a high-power multimode fiber laser. The cutting quality, in terms of kerf width and penetration depth, resulted from different scanning speeds and was studied and compared. The specimens used in this study were gabbro, granite, and diorite, which are widely applied in the construction industry because of their high compressive strength and beautiful textures. Energy-dispersive X-ray Spectroscopy (EDX) analyses were conducted to observe the chemical content of three different areas, the melting area, the burnt area, and a non-processed area, for each rock specimen. The study of the compositional changes in each area will also go over the cutting quality of each rock specimen at different scanning speeds. According to the experimental results, the kerf widths of the specimens gradually decrease as the scanning speeds increase. The penetration depths into the specimens sharply decrease as scanning speeds increase. From a study of their compositional changes, it is found that the cutting quality for each rock depends on their silica content. This study summarizes that the cutting quality for a rock specimen greatly depends on the scanning speed of the laser cutting.

Effect of Fluence and Multi-Pass on Groove Morphology and Process Efficiency of Laser Structuring for 3D Electrodes of Lithium-Ion Batteries.

Lithium-ion batteries (LIBs) are widely used as energy storage systems. With the growing interest in electric vehicles, battery performance related to traveling distance has become more important. Therefore, there are various studies going on to achieve high-power and high-energy batteries. Laser structuring of electrodes involves a groove being produced on electrodes by a laser. This technique was used to show that battery performance can be enhanced due to improving Li-ion diffusion. However, there is a lack of studies about the morphological variation of grooves and process efficiency in laser parameters in the laser structuring of electrodes. In this study, the LiFePO4 cathode is structured by a nanosecond laser to analyze the morphological variation of grooves and process efficiency depending on laser fluence and the number of passes. First, the various morphologies of grooves are formed by a combination of fluences and the number of passes. At a fluence of 0.86 J/cm2 and three passes, the maximum aspect ratio of 1.58 is achieved and the surface area of structured electrodes is greater than that of unstructured electrodes. Secondly, three ablation phenomena observed after laser structuring are classified according to laser parameters through SEM images and EDX analysis. Finally, we analyze the amount of active material removal and process efficiency during laser structuring. In conclusion, applying low fluence and multi-pass is assumed to be advantageous for laser structuring of electrodes.

The Effect of Laser Parameters on Cutting Metallic Materials.

This experimental study investigated the effect of laser parameters on the machining of SS41 and SUS304. The metallic materials play an important role in engineering applications. They are widely used in high-tech industries such as aerospace, automotive, and architecture. Due to the development of technology and high-tech industrialization, the various processing technologies are being developed with the requirement of high precision. However, the conventional cutting process is difficult to meet high precision processing. Therefore, to achieve high precision processing of the SS41 and SUS304, laser manufacturing has been applied. The current study investigated the process quality of laser cutting for SS41 and SUS304, with the usage of a continuous wave CO2 laser cutting system. The experimental variables are set to the laser cutting speed, laser power, and different engineering materials. The results are significantly affected by the laser parameters. As the result, the process quality of the laser cutting has been observed by measuring the top and bottom kerf widths, as well as the size of the melting zone and Heat Affected Zone (HAZ) according to volume energy. In addition, the evaluation of the laser processing parameters is significantly important to achieve optimal cutting quality. Therefore, we observed the correlation between the laser parameters and cutting quality. These were evaluated by analysis of variance (ANOVA) and multiple regression analysis. The experimental results of kerf top, kerf bottom, melting width, and HAZ on the laser parameters are properly predicted by multiple regression. In addition, the effect of laser parameters on the materials is determinant by the percentage of contribution of ANOVA.

The Effect of Using a Metal Tube on Laser Welding of the Battery Case and the Tab for Lithium-Ion Battery.

Given the drawbacks of the conventional welding methods in joining the battery case and tab in the lithium-ion battery, the laser welding technique using the metal tube has been introduced for the weld. The metal tube is supposed to contribute a positive effect including protection to the outside structure by blocking the injection of the spatters, and minimization of the contact gap between the battery case and table. However, the use of the metal tube is believed to cause the plume trapped inside and affect the intensity distribution of the laser gaussian beam. Through the observation and analysis in this study, both advantages and disadvantages of the application of the metal tube on the weld have been analyzed. The use of the metal tube prevents the ejection of the spatter to the outside of the welding zone, as well as minimize the air gap between the battery case and tab in the lap joint weld is also minimized. On the other hand, the trapped plume inside the metal tube and the reduction of the energy of the laser beam have been considered to cause significant changes in the morphology, mechanical, and electrical properties of the weld.

High-Power Fiber Laser Cutting for 50-mm-Thick Cement-Based Materials.

This experimental research highlights the applicability of laser cutting to cement-based materials using multimode fiber lasers. A 9 kW multimode fiber laser is used, and the experimental variables are the water-to-cement ratio, laser speed, and material compositions such as cement paste, cement mortar and ultra high performance concrete (UHPC). The laser cutting performance on the cement-based materials is investigated in the downward laser direction. The kerf width and penetration depth of the cement-based materials are quantitatively evaluated with the parameters in the surface and cross section of the specimens after the laser cutting. Moreover, the material removal zone of each specimen is compared in terms of the penetration shapes in the cross-sectional view. Based on experimental observations, the interaction mechanism between the laser and cement-based materials is proposed.

Microstructural Characteristics of Cement-Based Materials Fabricated Using Multi-Mode Fiber Laser.

Cement-based materials are the most prevalent construction materials, and the conventional cutting techniques are still mostly used for fabricating the materials. However, these conventional cutting methods could generate undesirable micro-cracks and remove unintentional structural sections. This experimental study aims to evaluate the effects of the new fabricating method using laser on the microstructural characteristics of the cement-based materials. The experimental variables are laser cutting speed, water to cement ratio and material compositions. In order to compare the microstructure before and after the laser interaction, the microstructure of the cut surface is observed through scanning electron microscopy/energy dispersive X-Ray (SEM/EDX). After the laser interaction, the Material Removed Zone (MRZ) and Heat Affected Zone (HAZ) are observed on the cut surface. In MRZ, it is found that the glassy layer is thickened by an increasing amount of silicate-based materials in cement-based materials. In addition, it concluded that the amount of silicate-based material mixed in the cement-based materials affects the laser cutting quality.

Design and manufacture of 3D cell culture plate for mass production of cell-spheroids.

A 3D cell culture is preferred to 2D cell culture since it allows cells to grow in all directions in vitro, similar to how they would in vivo. 3D cell culture plates currently used in tissue engineering research have limited access to control the geometry. Furthermore, 3D cell culture plate manufacturing methods are relatively complex, time-consuming, labor-intensive, and expensive. Therefore, a design and manufacturing method, which has relatively low cost, high throughput, and high size flexibility, is proposed. Cell culture plate was fabricated by computer aided design and manufacturing software using polydimethylsiloxane as a plate constituent. With the successfully-developed 3D cell culture plate, the morphology and viability of the cultured mesenchymal stem cells were tested.The mesenchymal stem cells seeded on the newly-fabricated 3D cell culture plate aggregated to form 3D spheroids within 24 h of incubation and well-maintained their viability. Thus, due to the capacity of mass production of the cell spheroids with a desired cell viability, the newly-fabricated plate has a great promise to prepare 3D cell spheroids for experimental as well as clinical applications.

Design of testbed and preliminary data for de-icing experiments using piezoelectric actuators.

The piezoelectric actuators, providing mechanical energy, are a good option to remove the ice efficiently. Therefore, a testbed for experiments are designed and the preliminary data of de-icing phenomena is provided. An ice specimen, formed from sterilized distilled water under -30 °C, is detached from the base materials after the voltage signal is engaged. The parameterized detachment phenomena and the analysis data are presented. The independent variables are ice thickness and frequency of the voltage input. The detachment distance is presented depending on the independent variables.

Understanding of BeCu Interaction Characteristics with a Variation of ns Laser-Pulse Duration.

An inspection process using a Spring Contact Probe (SCP) is an essential step in the semiconductor-manufacturing process. Many plungers, which are the main body of the SCP, are manufactured by a stamping process. After the stamping process, mechanical cutting is applied and the plunger body may be damaged. Thus, to improve cut quality and productivity while minimizing body damage, laser spot cutting can be used. To fully utilize this technology, it is necessary to investigate interaction characteristics of beryllium copper (BeCu) during laser spot cutting. Effects of a total irradiated laser-pulse energy (1 mJ ~1000 mJ ) and pulse duration (100 ns ~8 ns ) on the material-removal zone, thermal depth, and crater size are examined. The crater size can be affected by the localization of heating dominantly. An incubation model is applied to investigate the correlation between crater size and laser-pulse energy. Surface morphology characteristics such as edge separation, small particles, spatter motion, and soaring-up motion are observed.

Effect of Laser Speed on Cutting Characteristics of Cement-Based Materials.

The results of an experimental investigation on the physical and chemical characteristics of cement-based materials under laser interactions are presented. The laser cutting tests were conducted using a multi-mode continuous fiber laser with a laser power of 1 kW. The experimental variables were laser speed, water to cement ratio, and material compositions including cement paste, cement mortar, and ultra high-performance concrete (UHPC). In order to evaluate the mass removal mechanisms of cement-based materials under laser interactions, the effect of laser cutting was evaluated in terms of kerf width, penetration depth, and chemical composition changes before and after the interaction with laser using EDX analysis. The test results reveal that adding silica sand in cement-based materials leads to decreasing penetration depth and increasing kerf width. Unlike the cement paste and cement mortar series, UHPC specimens showed no discernible crack observed by the naked eye after laser interaction due to its high strength. Furthermore, the chemical analysis indicates that chemical composition changes were caused by various mechanisms including dehydration of calcium hydroxide and thermal decomposition of calcium carbonate.

Experimental Investigation of Multi-mode Fiber Laser Cutting of Cement Mortar.

This study successfully applied multi-mode laser cutting with the variation of the laser cutting speed to cement mortar for the first time. The effects of the amount of silica sand in the cement mortar on laser cutting are tested and analyzed. The kerf width and penetration depth of the specimens after laser cutting are investigated. As the laser cutting speed increases, the penetration depth decreases for both cement paste and cement mortar, whereas the kerf width becomes saturated and increases, respectively, for cement paste and cement mortar. Cross sections of the specimens are compared with illustrations. Top-view images of the cement mortar with indicators of the physical characteristics, such as re-solidification, burning, and cracks are examined, and the possible causes of these characteristics are explained. The optical absorption rates of cement-based materials are quantified at wide ranges of wavelength to compare the absorption rates in accordance with the materials compositions. The chemical composition variation before and after laser cutting is also compared by EDX (Energy Dispersive X-Ray) analysis. In addition to these observations, material removal mechanisms for cement mortar are proposed.

Dataset demonstrating effects of momentum transfer on sizing of current collector for lithium-ion batteries during laser cutting.

Material properties of copper and aluminum required for the numerical simulation are presented. Electrodes used for the (paper) are depicted. This study describes the procedures of how penetration depth, width, and absorptivity are obtained from the simulation. In addition, a file format extracted from the simulation to visualize 3D distribution of temperature, velocity, and melt pool geometry is presented.