Investigation of thermal effects of laser micromachining for APT and TEM specimen preparation: A modeling and experimental study.

Laser micromachining can serve as a coarse machining step during sample preparation for high-resolution characterization methods leading to swift sample preparation. However, selecting the right laser parameters is crucial to minimize the heat-affected zone, which can potentially compromise the microstructure of the specimen. This study focuses on evaluating the size of heat-affected zone in laser annular milling, aiming to ascertain a minimal scan diameter that safeguards the inner region of micropillars against thermal damage. A computational model based on the finite element method was utilized to simulate the laser heating process. To validate the simulation results, a picosecond pulsed laser is then used to machine the micropillars of Al and Si. The laser-machined samples were subjected to surface and microstructural analysis using Scanning Electron Microscope (SEM) and Electron Backscatter Diffraction (EBSD) scans. The length of heat affected zone obtained from simulations was approximately 6 µm for silicon and 12 µm for aluminum. The diameter of micropillars formed with laser machining was 10 µm for silicon 26 µm for aluminum. The core of the pillars was preserved with less than one degree of microstructural misorientations making it suitable for further processing for preparing specimens for techniques like APT and TEM. For silicon micropillars, the preserved central region has a diameter of 6 µm and for aluminum its around 20-24 µm. Additionally, the study determines the minimum scan diameter that can be achieved using the given laser machining setup across a range of common materials.

Computational Fluid Dynamics Modeling of Top-Down Digital Light Processing Additive Manufacturing.

Digital light processing (DLP) as a vat photopolymerization technique is one of the most popular three-dimensional (3D) printing methods, where chains are formed between liquid photocurable resin molecules to crosslink them and solidify the liquid resin using ultraviolet light. The DLP technique is inherently complex and the part accuracy depends on the process parameters that have to be chosen based on the fluid (resin) properties. In the present work, computational fluid dynamics (CFD) simulations are presented for top-down DLP as photocuring 3D printing. The effects of fluid viscosity, travelling speed of build part, travelling speed ratio (ratio of the up-to-down traveling speeds of build part), printed layer thickness, and travel distance considering 13 various cases are scrutinized by the developed model to obtain a stability time of fluid interface. The stability time describes the time it takes for the fluid interface to show minimum fluctuations. According to the simulations, a higher viscosity leads to prints with higher stability time. However, lower stability times in the printed layers are caused by a higher traveling speed ratio (TSR). The variation in settling times with TSR is extremely small in comparison to that of viscosity and travelling speed variations. As a result, a declining trend can be detected for the stability time by increasing the printed layer thickness, while by enhancing the travel distance values, the stability time demonstrated a descending pattern. In total, it was revealed that it is essential to choose optimal process parameters for achieving practical results. Moreover, the numerical model can assist in the optimizing the process parameters.

Methods and variables in Electrical discharge machining of titanium alloy - A review.

Titanium alloys are difficult to machine using conventional methods, therefore, nonconventional processes are often chosen in many applications. Electrical discharge machining (EDM) is one of those nonconventional processes that is used frequently for shaping titanium alloys with their respective pros and cons. However, a good understanding of this process is very difficult to achieve as research results are not properly connected and presented. Therefore, this study investigates different types of EDM processes such as, wire EDM, die-sink EDM, EDM drill and hybrid EDM used to machine titanium alloys. Machining mechanism, tool electrode, dielectric, materials removal rate (MRR), and surface integrity of all these processes are critically analysed and correlated based on the evidence accessible in literature. Machining process suffer from lower material removal rate and high tool wear while applied on titanium alloys. Formation of recast layer, heat affected zone and tool wear is common in all types of EDM processes. Additional challenge in wire EDM of titanium alloys is wire breakage under severe machining conditions. The formation of TiC and TiO2 are noticed in recast layer depending on the type of dielectrics. Removal of debris from small holes during EDM drilling is a challenge. All these restricts the applications EDMed titanium alloys in high-tech applications such as, aerospace and biomedical areas. Most of these challenges come up due to extraordinary properties such as, low thermal conductivity, high melting point and high hardness, of titanium alloys. Though hybrid EDM has been introduced and there is some work on simulation of EDM process, further developments in EDM of this alloy is required for widening the application of this methods.