Formation of multiscale surface structures on nickel via above surface growth and below surface growth mechanisms using femtosecond laser pulses

Machine Learning Classification of Self-Organized Surface Structures in Ultrashort-Pulse Laser Processing Based on Light Microscopic Images

In ultrashort-pulsed laser processing, surface modification is subject to complex laser and scanning parameter studies. In addition, quality assurance systems for monitoring surface modification are still lacking. Automated laser processing routines featuring machine learning (ML) can help overcome these limitations, but they are largely absent in the literature and still lack practical applications. This paper presents a new methodology for machine learning classification of self-organized surface structures based on light microscopic images. For this purpose, three application-relevant types of self-organized surface structures are fabricated using a 300 fs laser system on hot working tool steel and stainless-steel substrates. Optical images of the hot working tool steel substrates were used to learn a classification algorithm based on the open-source tool Teachable Machine from Google. The trained classification algorithm achieved very high accuracy in distinguishing the surface types for the hot working steel substrate learned on, as well as for surface structures on the stainless-steel substrate. In addition, the algorithm also achieved very high accuracy in classifying the images of a specific structure class captured at different optical magnifications. Thus, the methodology proposed represents a simple and robust automated classification of surface structures that can be used as a basis for further development of quality assurance systems, automated process parameter recommendation, and inline laser parameter control.

Microscopic mechanisms for initiation and evolution of femtosecond laser-induced columnar structures above the surface level of aluminum

A better understanding of the formation of femtosecond (fs) laser-induced surface structures is key to the control of their morphological profiles for desired surface functionalities on metals. In this work, with fs laser pulse irradiation, the two stages of formation mechanisms of the columnar structures (CSs) grown above the surface level are investigated on pure Al plates in ambient air. Here, we find that the redeposition of ablated microscale clusters following fs laser pulses of irradiation acts as the nucleation sites of CS formation, which strongly affects their location and density within the laser spot. Furthermore, we suggest their structural growths and morphological shape changes are directly associated with the competition among four laser-impact hydrodynamical phenomena: laser ablation, subsequent molten metal flow, particles' redeposition, and metal vapor condensation with continued pulse irradiation.

Surface Modification of Brass via Ultrashort Pulsed Direct Laser Interference Patterning and Its Effect on Bacteria-Substrate Interaction

In recent decades, antibiotic resistance has become a crucial challenge for human health. One potential solution to this problem is the use of antibacterial surfaces, i.e., copper and copper alloys. This study investigates the antibacterial properties of brass that underwent topographic surface functionalization via ultrashort pulsed direct laser interference patterning. Periodic line-like patterns in the scale range of single bacterial cells were created on brass with a 37% zinc content to enhance the contact area for rod-shaped Escherichia coli (E. coli). Although the topography facilitates attachment of bacteria to the surface, reduced killing rates for E. coli are observed. In parallel, a high-resolution methodical approach was employed to explore the impact of laser-induced topographical and chemical modifications on the antibacterial properties. The findings reveal the underlying role of the chemical modification concerning the antimicrobial efficiency of the Cu-based alloy within the superficial layers of a few hundred nanometers. Overall, this study provides valuable insight into the effect of alloy composition on targeted laser processing for antimicrobial Cu-surfaces, which facilitates the thorough development and optimization of the process concerning antimicrobial applications.

Laser Treatment of Surfaces for Pool Boiling Heat Transfer Enhancement

The laser treatment of surfaces enables the alteration of their morphology and makes them suitable for various applications. This paper discusses the use of a laser beam to develop surface features that enhance pool boiling heat transfer. Two types of structures (in the 'macro' and 'micro' scale) were created on the samples: microfins (grooves) and surface roughness. The impact of the pulse duration and scanning velocity on the height of the microfins and surface roughness at the bottom of the grooves was analyzed with a high precision optical profilometer and microscope. The results indicated that the highest microfins and surface roughness were obtained with a pulse duration of 250 ns and scanning velocity of 200 mm/s. In addition, the influence of the 'macro' and 'micro' scale modifications on the boiling heat transfer of distilled water and ethyl alcohol was studied on horizontal samples heated with an electric heater. The largest enhancement was obtained for the highest microfins and roughest surfaces, especially at small superheats. Heat flux dissipated from the samples containing microfins of 0.4 mm height was, maximally, over three times (for water) and two times (for ethanol) higher than for the samples with smaller microfins (0.2 mm high). Thus, a modification of a selected model of boiling heat transfer was developed so that it would be applicable to laser-processed surfaces. The correlation proved to be quite successful, with almost all experimental data falling within the ±100% agreement bands.

Impact of Pre-Patterned Structures on Features of Laser-Induced Periodic Surface Structures

The efficiency of light coupling to surface plasmon polariton (SPP) represents a very important issue in plasmonics and laser fabrication of topographies in various solids. To illustrate the role of pre-patterned surfaces and impact of laser polarisation in the excitation of electromagnetic modes and periodic pattern formation, Nickel surfaces are irradiated with femtosecond laser pulses of polarisation perpendicular or parallel to the orientation of the pre-pattern ridges. Experimental results indicate that for polarisation parallel to the ridges, laser induced periodic surface structures (LIPSS) are formed perpendicularly to the pre-pattern with a frequency that is independent of the distance between the ridges and periodicities close to the wavelength of the excited SPP. By contrast, for polarisation perpendicular to the pre-pattern, the periodicities of the LIPSS are closely correlated to the distance between the ridges for pre-pattern distance larger than the laser wavelength. The experimental observations are interpreted through a multi-scale physical model in which the impact of the interference of the electromagnetic modes is revealed.

Near-Infrared Femtosecond Laser Ablation of Au-Coated Ni: Effect of Organic Fluids and Water on Crater Morphology, Ablation Efficiency and Hydrodynamic Properties of NiAu Nanoparticles

Scanning electron microscopy (SEM) and profilometry of the crater morphology and ablation efficiency upon femtosecond laser ablation of Au-coated Ni targets in various fluids revealed a pronounced dependence on the ablation medium. For ethanol, a sufficient ablation efficiency was obtained, whereas for 2-butanol a higher efficiency indicated stronger laser-target interaction. Hierarchical features in the crater periphery pointed to asymmetrical energy deposition or a residual effect of the Coulomb-explosion-initiating ablation. Significant beam deviation in 2-butanol caused maximum multiple scattering at the crater bottom. The highest values of microstrain and increased grain size, obtained from Williamson-Hall plots, indicated the superposition of mechanical stress, defect formation and propagation of fatigue cracks in the crater circumference. For n-hexane, deposition of frozen droplets in the outer crater region suggested a femtosecond-laser-induced phase explosion. A maximum ablation depth occurred in water, likely due to its high cooling efficiency. Grazing incidence micro X-ray diffraction (GIXRD) of the used target showed residual carbon and partial surface oxidation. The produced nanoparticle colloids were examined by multiangle dynamic light scattering (DLS), employing larger scattering angles for higher sensitivity toward smaller nanoparticles. The smallest nanoparticles were obtained in 2-butanol and ethanol. In n-hexane, floating carbon flakes originated from femtosecond-laser-induced solvent decomposition.

In Situ Collection of Nanoparticles during Femtosecond Laser Machining in Air

Nanoparticles generated during laser material processing are often seen as annoying side products, yet they might find useful application upon proper collection. We present a parametric study to identify the dominant factors in nanoparticle removal and collection with the goal of establishing an in situ removal method during femtosecond laser machining. Several target materials of different electrical resistivity, such as Cu, Ti, and Si were laser machined at a relatively high laser fluence. Machining was performed under three different charge conditions, i.e., machining without an externally applied charge (alike atmospheric pulsed laser deposition (PLD)) was compared to machining with a floating potential and with an applied field. Thereby, we investigated the influence of three different charge conditions on the behavior of laser-generated nanoparticles, in particular considering plume deflection, nanoparticle accumulation on a collector plate and their redeposition onto the target. We found that both strategies, machining under a floating potential or under an applied field, were effective for collecting laser-generated nanoparticles. The applied field condition led to the strongest confinement of the nanoparticle plume and tightest resulting nanoparticle collection pattern. Raster-scanning direction was found to influence the nanoparticle collection pattern and ablation depth. However, the laser-processed target surface remained unaffected by the chosen nanoparticle collection strategy. We conclude that machining under a floating potential or an applied field is a promising setup for removing and collecting nanoparticles during the machining process, and thus provides an outlook to circular waste-free laser process design.

Multiple Wetting-Dewetting States of a Water Droplet on Dual-Scale Hierarchical Structured Surfaces

Surfaces with microscale roughness can entail dual-scale hierarchical structures such as the recently reported nano/microstructured surfaces produced in the laboratory (Wang et al. Nature2020, 582, 55-57). However, how the dual-scale hierarchical structured surface affects the apparent wetting/dewetting states of a water droplet, and the transitions between the states are still largely unexplored. Here, we report a systematic large-scale molecular dynamics (MD) simulation study on the wetting/dewetting states of water droplets on various dual-scale nano/near-submicrometer structured surfaces. To this end, we devise slab-water/slab-substrate model systems with a variety of dual-scale surface structures and with different degrees of intrinsic wettability (as measured based on the counterpart smooth surface). The dual-scale hierarchical structure can be described as "nanotexture-on-near-submicrometer-hill". Depending on three prototypical nanotextures, our MD simulations reveal five possible wetting/dewetting states for a water droplet: (i) Cassie state; (ii) infiltrated upper-valley state; (iii) immersed nanotexture-on-hill state; (iv) infiltrated valley state; and (v) Wenzel state. The transitions between these wetting/dewetting states are strongly dependent on the intrinsic wettability (E _in), the initial location of the water droplet, the height of the nanotextures (H ₁), and the spacing between nanotextures (W ₁). Notably, E _in-H ₁ and E _in-W ₁ diagrams show that regions of rich wetting/dewetting states can be identified, including regions where between one to five states can coexist.

Large-Beam Picosecond Interference Patterning of Metallic Substrates

In this paper, we introduce a method to efficiently use a high-energy pulsed 1.7 ps HiLASE Perla laser system for two beam interference patterning. The newly developed method of large-beam interference patterning permits the production of micro and sub-micron sized features on a treated surface with increased processing throughputs by enlarging the interference area. The limits for beam enlarging are explained and calculated for the used laser source. The formation of a variety of surface micro and nanostructures and their combinations are reported on stainless steel, invar, and tungsten with the maximum fabrication speed of 206 cm²/min. The wettability of selected hierarchical structures combining interference patterns with 2.6 µm periodicity and the nanoscale surface structures on top were analyzed showing superhydrophobic behavior with contact angles of 164°, 156°, and 150° in the case of stainless steel, invar, and tungsten, respectively.

The Role of the Surface Nano-Roughness on the Wettability Performance of Microstructured Metallic Surface Using Direct Laser Interference Patterning

Superhydrophobic natural surfaces usually have multiple levels of structure hierarchy, particularly microstructures covered with nano-roughness. The multi-scale nature of such a surface reduces the wetting of water and oils, and supports self-cleaning properties. In this work, in order to broaden our understanding of the wetting properties of technical surfaces, biomimetic surface patterns were fabricated on stainless steel with single and multi-scale periodic structures using direct laser interference patterning (DLIP). Micropillars with a spatial period of 5.5 µm and a structural depth of 4.2 µm were fabricated and covered by a sub-micro roughness by using ultrashort laser pulses, thus obtaining a hierarchical geometry. In order to distinguish the influence of the different features on the wettability behavior, a nanosecond laser source was used to melt the nano-roughness, and thus to obtain single-scale patterns. Then, a systematic comparison between the single- and multi-scale structures was performed. Although, the treated surfaces showed hydrophilic behavior directly after the laser treatment, over time they reached a steady-state hydrophobic condition. However, the multi-scale structured metal showed a contact angle 31° higher than the single-scale geometry when the steady-state conditions were reached. Furthermore, the impact of the surface chemistry was investigated by energy dispersive X-ray spectroscopy (EDX) and X-ray photoelectron spectroscopy (XPS) analyses. Finally, a hydrophobizing agent was applied to the laser treated samples in order to further enhance the water contact angles and to determine the pure contribution of the surface topography. In the latter case, the multi-scale periodic microstructures reached static contact angles of 152° ± 2° and a contact angle hysteresis of only 4° ± 2°, while the single-scale structures did not show superhydrophobic behavior. These results definitely suggest that multi-scale DLIP structures in conjunction with a surface chemistry modification can promote a superhydrophobic regime.

Is dropwise condensation feasible? A review on surface modifications for continuous dropwise condensation and a profitability analysis

The interest in surface treatments promoting dropwise condensation has grown exponentially in the past decades. Savings in the operating and maintenance costs of steam processes involving phase changes are promised. Numerous surface preparation methods allow the formation of droplets during condensation. However, stable dropwise condensation has been hardly realized in industrial applications. This review aims to highlight the surface preparation techniques that promote dropwise condensation. It emphasizes on their durability and the resulting stability of dropwise condensation. Furthermore, the possibilities of implementation at an industrial level are discussed, apart from evaluating the economic feasibility through a case study. Despite years of research and numerous surface design possibilities, dropwise condensation cannot be maintained: coating deterioration and fluctuating process conditions commonly lead to surface flooding within hours or weeks. A more profound understanding of the mechanisms of dropwise condensation and innovative design concepts for self-renewing heat transfer surfaces may diminish encountered challenges.

Additive and Substractive Surface Structuring by Femtosecond Laser Induced Material Ejection and Redistribution

A novel additive surface structuring process is devised, which involves localized, intense femtosecond laser irradiation. The irradiation induces a phase explosion of the material being irradiated, and a subsequent ejection of the ablative species that are used as additive building blocks. The ejected species are deposited and accumulated in the vicinity of the ablation site. This redistribution of the material can be repeated and controlled by raster scanning and multiple pulse irradiation. The deposition and accumulation cause the formation of µm-scale three-dimensional structures that surpass the initial surface level. The above-mentioned ablation, deposition, and accumulation all together constitute the proposed additive surface structuring process. In addition, the geometry of the three-dimensional structures can be further modified, if desirable, by a subsequent substractive ablation process. Microstructural analysis reveals a quasi-seamless conjugation between the surface where the structures grow and the structures additively grown by this method, and hence indicates the mechanic robustness of these structures. As a proof of concept, a sub-mm sized re-entrant structure and pillars are fabricated on aluminum substrate by this method. Single units as well as arrayed structures with arbitrary pattern lattice geometry are easily implemented in this additive surface structuring scheme. Engineered surface with desired functionalities can be realized by using this means, i.e., a surface with arrayed pillars being rendered with superhydrophobicity.

Biomimetic Liquid-Repellent Surfaces by Ultrafast Laser Processing

This review is focused on the realization of liquid-repellent surfaces, inspired by two biological models: “dry” superhydrophobic leaves and “slippery” liquid-repellent carnivorous plants using ultrafast laser processing. After a short introduction to a biomimetic development process, an overview of the laser-fabricated structures, which were intensively used for the realization of biomimetic “dry” and “slippery” liquid-repellent surfaces, is given. The influence of process parameters on the structure morphology is discussed. A summary of superhydrophobic and liquid-repellent modifications of different materials (metals, semiconductors, and polymers), including wettability characteristics and processing details, is provided. The technological applications of laser-structured liquid-repellent surfaces are discussed.

Effects of Femtosecond Laser Surface Processed Nanoparticle Layers on Pool Boiling Heat Transfer Performance

An experimental investigation of the effects of layers of nanoparticles formed during femtosecond laser surface processing (FLSP) on pool boiling heat transfer performance has been conducted. Five different stainless steel 304 samples with slightly different surface features were fabricated through FLSP, and pool boiling heat transfer experiments were carried out to study the heat transfer characteristics of each surface. The experiments showed that the layer(s) of nanoparticles developed during the FLSP processes, which overlay FLSP self-organized microstructures, can either improve or degrade boiling heat transfer coefficients (HTC) depending on the overall thickness of the layer(s). This nanoparticle layer thickness is an indirect result of the type of microstructure created. The HTCs were found to decrease with increasing nanoparticle layer thickness. This trend has been attributed to added thermal resistance. Using a focused ion beam milling process and transmission electron microscopy (TEM), the physical and chemical properties of the nanoparticle layers were characterized and used to explain the observed heat transfer results. Results suggest that there is an optimal nanoparticle layer thickness and material composition such that both the HTCs and critical heat flux (CHF) are enhanced.

Investigation of femtosecond laser induced ripple formation on copper for varying incident angle

The hydrodynamic mechanisms associated with the formation of femtosecond laser induced ripples on copper for two angles of incidence are reported. Laser pulse length used for this work is 35 fs. A revised two-temperature model is presented that comprises transient changes of optical characteristics during the irradiation with femtosecond pulses to model relaxation processes and thermal response in bulk copper. The theoretical model takes into account the fluid flow dynamics that result in ripple periods shorter than the wavelength of the surface plasmon polaritons. Theoretical and experimental results are reported for incident angles of 0° and 45° relative to the surface normal. There is agreement between the experimentally measured and the theoretically predicted ripple periodicity for 50 pulses at 0° incidence. By contrast, for 100 pulses at 0° incidence, and 50 and 100 pulses at 45° incidence, the experimentally measured ripples have a larger period than the one predicted by the model while the trends in period with increased incident angle, and increased fluence are in agreement between the experimental and the theoretical results.

Formation of aggregated nanoparticle spheres through femtosecond laser surface processing

A detailed structural and chemical analysis of a class of self-organized surface structures, termed aggregated nanoparticle spheres (AN-spheres), created using femtosecond laser surface processing (FLSP) on silicon, silicon carbide, and aluminum is reported in this paper. AN-spheres are spherical microstructures that are 20-100 μm in diameter and are composed entirely of nanoparticles produced during femtosecond laser ablation of material. AN-spheres have an onion-like layered morphology resulting from the build-up of nanoparticle layers over multiple passes of the laser beam. The material properties and chemical composition of the AN-spheres are presented in this paper based on scanning electron microscopy (SEM), focused ion beam (FIB) milling, transmission electron microscopy (TEM), and energy dispersive x-ray spectroscopy (EDX) analysis. There is a distinct difference in the density of nanoparticles between concentric rings of the onion-like morphology of the AN-sphere. Layers of high-density form when the laser sinters nanoparticles together and low-density layers form when nanoparticles redeposit while the laser ablates areas surrounding the AN-sphere. The dynamic nature of femtosecond laser ablation creates a variety of nanoparticles that make-up the AN-spheres including Si/C core-shell, nanoparticles that directly fragmented from the base material, nanoparticles with carbon shells that retarded oxidation, and amorphous, fully oxidized nanoparticles.

Growth mechanisms of multiscale, mound-like surface structures on titanium by femtosecond laser processing

Femtosecond laser surface processing (FLSP) can be used to functionalize many surfaces, imparting specialized properties such as increased broadband optical absorption or super-hydrophobicity/-hydrophilicity. In this study, the subsurface microstructure of a series of mound-like FLSP structures formed on commercially pure titanium using five combinations of laser fluence and cumulative pulse counts was studied. Using a dual beam Scanning Electron Microscope with a Focused Ion Beam, the subsurface microstructure for each FLSP structure type was revealed by cross-sectioning. The microstructure of the mounds formed using the lowest fluence value consists of the original Ti grains. This is evidence that preferential laser ablation is the primary formation mechanism. However, the underlying microstructure of mounds produced using higher fluence values was composed of a distinct smaller-grained α-Ti region adjacent to the original larger Ti grains remaining deeper beneath the surface. This layer was attributed to resolidification of molten Ti from the hydrodynamic Marangoni effect driven fluid flow of molten Ti, which is the result of the femtosecond pulse interaction with the material.

Terahertz multilevel phase Fresnel lenses fabricated by laser patterning of silicon

Multilevel phase Fresnel lenses (MPFLs) with a high numerical aperture for 0.58 THz frequencies were developed. The components based on a monocrystalline silicon wafer are prepared by patterning by a high-speed industrial-scale laser direct writing (LDW) system. Two consistent series of the terahertz-MPFLs with phase quantization levels varying between 2 and the continuous kinoform shape for the focal lengths of 5 and 10 mm were produced employing inherent flexibility of the LDW fabrication process. The focusing performance was studied at the optimal 0.58 THz frequency using a Gaussian beam profile and scanning 2D intensity distribution with a terahertz detector along the optical axis. The efficiency of the terahertz-MPFL was found to be dependent of the number of subzones. The position and orientation angles of the patterned plane of the silicon wafer were considered to reduce the effect of standing waves formation in the experiment.

Micro/nanostructures formation by femtosecond laser surface processing on amorphous and polycrystalline Ni60Nb40

Femtosecond laser surface processing is a technology that can be used to functionalize many surfaces, imparting specialized properties such as increased broadband optical absorption or superhydrophilicity/superhydrophobicity. In this study, two unique classes of surface structures, below surface growth (BSG) and above surface growth (ASG) mounds, were formed by femtosecond laser surface processing on amorphous and polycrystalline Ni60Nb40 with two different grain sizes. Cross sectional imaging of these mounds revealed thermal evidence of the unique formation processes for each class of surface structure. BSG mounds formed on all three substrates using the same laser parameters had similar surface morphology. The microstructures in the mounds were unaltered compared with the substrate before laser processing, suggesting their formation was dominated by preferential valley ablation. ASG mounds had similar morphology when formed on the polycrystalline Ni60Nb40 substrates with 100 nm and 2 [H9262]m grain size. However, the ASG mounds had significantly wider diameter and higher peak-to-valley heights when the substrate was amorphous Ni60Nb40. Hydrodynamic melting was primarily responsible for ASG mound formation. On amorphous Ni60Nb40 substrates, the ASG mounds are most likely larger due to lower thermal diffusivity. There was clear difference in growth mechanism of femtosecond laser processed BSG and ASG mounds, and grain size does not appear to be a factor.

Effect of Repetition Rate on Femtosecond Laser-Induced Homogenous Microstructures

We report on the effect of repetition rate on the formation and surface texture of the laser induced homogenous microstructures. Different microstructures were micromachined on copper (Cu) and titanium (Ti) using femtosecond pulses at 1 and 10 kHz. We studied the effect of the repetition rate on structure formation by comparing the threshold accumulated pulse (FΣpulse) values and the effect on the surface texture through lacunarity analysis. Machining both metals at low FΣpulse resulted in microstructures with higher lacunarity at 10 kHz compared to 1 kHz. On increasing FΣpulse, the microstructures showed higher lacunarity at 1 kHz. The effect of the repetition rate on the threshold FΣpulse values were, however, considerably different on the two metals. With an increase in repetition rate, we observed a decrease in the threshold FΣpulse on Cu, while on Ti we observed an increase. These differences were successfully allied to the respective material characteristics and the resulting melt dynamics. While machining Ti at 10 kHz, the melt layer induced by one laser pulse persists until the next pulse arrives, acting as a dielectric for the subsequent pulse, thereby increasing FΣpulse. However, on Cu, the melt layer quickly resolidifies and no such dielectric like phase is observed. Our study contributes to the current knowledge on the effect of the repetition rate as an irradiation parameter.

Experimental explanation of the formation mechanism of surface mound-structures by femtosecond laser on polycrystalline Ni60Nb40

Femtosecond laser surface processing (FLSP) is an emerging technique for creating functionalized surfaces with specialized properties, such as broadband optical absorption or superhydrophobicity/superhydrophilicity. It has been demonstrated in the past that FLSP can be used to form two distinct classes of mound-like, self-organized micro/nanostructures on the surfaces of various metals. Here, the formation mechanisms of below surface growth (BSG) and above surface growth (ASG) mounds on polycrystalline Ni60Nb40 are studied. Cross-sectional imaging of these mounds by focused ion beam milling and subsequent scanning electron microscopy revealed evidence of the unique formation processes for each class of microstructure. BSG-mound formation during FLSP did not alter the microstructure of the base material, indicating preferential valley ablation as the primary formation mechanism. For ASG-mounds, the microstructure at the peaks of the mounds was clearly different from the base material. Transmission electron microscopy revealed that hydrodynamic melting of the surface occurred during FLSP under ASG-mound forming conditions. Thus, there is a clear difference in the formation mechanisms of ASG- and BSG-mounds during FLSP.

Ripple formation on nickel irradiated with radially polarized femtosecond beams

We report on the morphological effects induced by the inhomogeneous absorption of radially polarized femtosecond laser irradiation of nickel (Ni) in sub-ablation conditions. A theoretical prediction of the morphology profile is performed, and the role of surface plasmon excitation in the production of self-formed periodic ripple structures is evaluated. Results indicate a smaller periodicity of the ripples profile compared to that attained under linearly polarized irradiation conditions. A combined hydrodynamical and thermoelastic model is presented in laser beam conditions that lead to material melting. The simulation results are presented to be in good agreement with the experimental findings. The ability to control the size of the morphological changes via modulating the beam polarization may provide an additional route for controlling and optimizing the outcome of laser micro-processing.

Enhanced pool-boiling heat transfer and critical heat flux on femtosecond laser processed stainless steel surfaces

In this paper, we present an experimental investigation of pool boiling heat transfer on multiscale (micro/nano) functionalized metallic surfaces. Heat transfer enhancement in metallic surfaces is very important for large scale high heat flux applications like in the nuclear power industry. The multiscale structures were fabricated via a femtosecond laser surface process (FLSP) technique, which forms self-organized mound-like microstructures covered by layers of nanoparticles. Using a pool boiling experimental setup with deionized water as the working fluid, both the heat transfer coefficients and critical heat flux were investigated. A polished reference sample was found to have a critical heat flux of 91 W/cm² at 40 °C of superheat and a maximum heat transfer coefficient of 23,000 W/m² K. The processed samples were found to have a maximum critical heat flux of 142 W/cm² at 29 °C and a maximum heat transfer coefficient of 67,400 W/m² K. It was found that the enhancement of the critical heat flux was directly related to the wetting and wicking ability of the surface which acts to replenish the evaporating liquid and delay critical heat flux. The heat transfer coefficients were also found to increase when the surface area ratio was increased as well as the microstructure peak-to-valley height. Enhanced nucleate boiling is the main heat transfer mechanism, and is attributed to an increase in surface area and nucleation site density.

Large-area one-step assembly of three-dimensional porous metal micro/nanocages by ethanol-assisted femtosecond laser irradiation for enhanced antireflection and hydrophobicity

The capability to realize 2D-3D controllable metallic micro/nanostructures is of key importance for various fields such as plasmonics, electronics, bioscience, and chemistry due to unique properties such as electromagnetic field enhancement, catalysis, photoemission, and conductivity. However, most of the present techniques are limited to low-dimension (1D-2D), small area, or single function. Here we report the assembly of self-organized three-dimensional (3D) porous metal micro/nanocages arrays on nickel surface by ethanol-assisted femtosecond laser irradiation. The underlying formation mechanism was investigated by a series of femtosecond laser irradiation under exposure time from 5 to 30 ms. We also demonstrate the ability to control the size of micro/nanocage arrays from 0.8 to 2 μm by different laser pulse energy. This method features rapidness (∼10 min), simplicity (one-step process), and ease of large-area (4 cm(2) or more) fabrication. The 3D cagelike micro/nanostructures exhibit not only improved antireflection from 80% to 7% but also enhanced hydrophobicity from 98.5° to 142° without surface modification. This simple technique for 3D large-area controllable metal microstructures will find great potential applications in optoelectronics, physics, and chemistry.

Self‑propelled droplets on heated surfaces with angled self‑assembled micro/nanostructures

Directional and ratchet-like functionalized surfaces can induce liquid transport without the use of an external force. In this paper, we investigate the motion of liquid droplets near the Leidenfrost temperature on functionalized self-assembled asymmetric microstructured surfaces. The surfaces, which have angled microstructures, display unidirectional properties. The surfaces are fabricated on stainless steel through the use of a femtosecond laser-assisted process. Through this process, mound-like microstructures are formed through a combination of material ablation, fluid flow, and material redeposition. In order to achieve the asymmetry of the microstructures, the femtosecond laser is directed at an angle with respect to the sample surface. Two surfaces with microstructures angled at 45° and 10° with respect to the surface normal were fabricated. Droplet experiments were carried out with deionized water and a leveled hot plate to characterize the directional and self-propelling properties of the surfaces. It was found that the droplet motion direction is opposite of that for a surface with conventional ratchet microstructures reported in the literature. The new finding could not be explained by the widely accepted mechanism of asymmetric vapor flow. A new mechanism for a self-propelled droplet on asymmetric three-dimensional self-assembled microstructured surfaces is proposed.

Extraordinary shifts of the Leidenfrost temperature from multiscale micro/nanostructured surfaces

In the present work, the effects of surface chemistry and micro/nanostructuring on the Leidenfrost temperature are experimentally investigated. The functional surfaces were fabricated on a 304 stainless steel surface via femtosecond laser surface processing (FLSP). The droplet lifetime experimental method was employed to determine the Leidenfrost temperature for both machine-polished and textured surfaces. A precision dropper was used to control the droplet size to 4.2 μL and surface temperatures were measured by means of an embedded thermocouple. Extraordinary shifts in the Leidenfrost temperatures, as high as 175 °C relative to the polished surface, were observed with the laser-processed surfaces. These extraordinary shifts were attributed to nanoporosity, reduction in contact angle, intermittent liquid/solid contacts, and capillary wicking actions resulting from the presence of self-assembled nanoparticles formed on the surfaces. In addition to the shift in the Leidenfrost temperature, significant enhancement of the heat transfer in the film boiling regime was also observed for the laser-processed surfaces; water droplet evaporation times were reduced by up to 33% for a surface temperature of 500 °C.