High-Rate Laser Surface Texturing for Advanced Tribological Functionality

Simulation and Structural Analysis of a Flexible Coupling Bionic Desorption Mechanism Based on the Engineering Discrete Element Method

Soil adhesion is one of the important factors affecting the working stability and quality of agricultural machinery. The application of bionic non-smooth surfaces provides a novel idea for soil anti-adhesion. The parameters of sandy loam with 21% moisture content were calibrated by the Engineering Discrete Element Method (EDEM). The final simulated soil repose angle was highly consistent with the measured soil repose angle, and the obtained regression equation of the soil repose angle provides a numerical reference for the parameter calibration of different soils. By simulating the sinusoidal swing of a sandfish, it was found that the contact interface shows the phenomenon of stress concentration and periodic change, which reflects the effectiveness of flexible desorption and soil anti-adhesion. The moving resistance of the wedge with different wedge angles and different serrated structures was simulated. Finally, it was found that a 40° wedge with a high-tail sparse staggered serrated structure on the surface has the best drag reduction effect, and the drag reduction is about 10.73%.

Tailoring the Coefficient of Friction by Direct Laser Writing Surface Texturing

The modification of the surface topography at the micro- and nanoscale is a widely established as one of the best ways to engineering the surface of materials, to improve the tribological performances of materials in terms of load capacity and friction. The present paper reviews the state of the art on laser surface texturing by exploiting the technique of direct laser writing for tailoring the coefficient of friction, highlighting the effect of the textures' arrangement on the lubricated conformal and non-conformal contact behavior.

Laser-Based Selective Material Processing for Next-Generation Additive Manufacturing

The connection between laser-based material processing and additive manufacturing is quite deeply rooted. In fact, the spark that started the field of additive manufacturing is the idea that two intersecting laser beams can selectively solidify a vat of resin. Ever since, laser has been accompanying the field of additive manufacturing, with its repertoire expanded from processing only photopolymer resin to virtually any material, allowing liberating customizability. As a result, additive manufacturing is expected to take an even more prominent role in the global supply chain in years to come. Herein, an overview of laser-based selective material processing is presented from various aspects: the physics of laser-material interactions, the materials currently used in additive manufacturing processes, the system configurations that enable laser-based additive manufacturing, and various functional applications of next-generation additive manufacturing. Additionally, current challenges and prospects of laser-based additive manufacturing are discussed.

Scanning Strategies in Laser Surface Texturing: A Review

Laser surface texturing (LST) is one of the most promising technologies for controllable surface structuring and the acquisition of specific physical surface properties needed in functional surfaces. The quality and processing rate of the laser surface texturing strongly depend on the correct choice of a scanning strategy. In this paper, a comparative review of the classical and recently developed scanning strategies of laser surface texturing is presented. The main attention is paid to maximal processing rate, precision and existing physical limitations. Possible ways of further development of the laser scanning strategies are proposed.

Tribological Behavior of Bioinspired Surfaces

Energy losses due to various tribological phenomena pose a significant challenge to sustainable development. These energy losses also contribute toward increased emissions of greenhouse gases. Various attempts have been made to reduce energy consumption through the use of various surface engineering solutions. The bioinspired surfaces can provide a sustainable solution to address these tribological challenges by minimizing friction and wear. The current study majorly focuses on the recent advancements in the tribological behavior of bioinspired surfaces and bio-inspired materials. The miniaturization of technological devices has increased the need to understand micro- and nano-scale tribological behavior, which could significantly reduce energy wastage and material degradation. Integrating advanced research methods is crucial in developing new aspects of structures and characteristics of biological materials. Depending upon the interaction of the species with the surrounding, the present study is divided into segments depicting the tribological behavior of the biological surfaces inspired by animals and plants. The mimicking of bio-inspired surfaces resulted in significant noise, friction, and drag reduction, promoting the development of anti-wear and anti-adhesion surfaces. Along with the reduction in friction through the bioinspired surface, a few studies providing evidence for the enhancement in the frictional properties were also depicted.

Special Issue "Advanced Pulse Laser Machining Technology"

"Advanced Pulse Laser Machining Technology" is a rapidly growing field that can be tailored to special industrial and scientific applications [...].

Potential hazards and mitigation of X-ray radiation generated by laser-induced plasma from research-grade laser systems

A large range of laser-matter applications employ ultrashort pulses and high laser intensity. Such processes can lead to unrequired X-ray generation, which represents a hazardous radiation factor even for common laboratory research-grade laser systems. We present here an analysis of the radiation dose rate and X-ray spectrum emitted during ablation of a rotating copper cylinder with respect to several laser parameters. The results show that focused sub-picosecond pulses with intensity above 10¹³ W/cm² can exceed the annual irradiation limit even in one hour, requiring appropriate shielding for the safety of the researchers.

Formation of Nano- and Micro-Scale Surface Features Induced by Long-Range Femtosecond Filament Laser Ablation

In this work, we study the characteristics of femtosecond-filament-laser–matter interactions and laser-induced periodic surface structures (LIPSS) at a beam-propagation distance up to 55 m. The quantification of the periodicity of filament-induced self-organized surface structures was accomplished by SEM and AFM measurements combined with the use of discrete two-dimensional fast Fourier transform (2D-FFT) analysis, at different filament propagation distances. The results show that the size of the nano-scale surface features increased with ongoing laser filament processing and, further, periodic ripples started to form in the ablation-spot center after irradiation with five spatially overlapping pulses. The effective number of irradiating filament pulses per spot area affected the developing surface texture, with the period of the low spatial frequency LIPSS reducing notably at a high pulse number. The high regularity of the filament-induced ripples was verified by the demonstration of the angle-of-incidence-dependent diffraction of sunlight. This work underlines the potential of long-range femtosecond filamentation for energy delivery at remote distances, with suppressed diffraction and long depth focus, which can be used in biomimetic laser surface engineering and remote-sensing applications.

Effect of Surface Texture on the Sliding Pair Lubrication Efficiency

The paper presents certain problems related to the lubrication of textured surfaces. It was noted that for a specific load, the lubrication effectiveness will depend on the shape, size and mutual distribution of the texture’s elements. Proposals for determining the lubrication irregularity parameters were presented for textures with a rectangular mesh and round recesses. The experimental part presents the laser texturing methodology, tribological testing methodology and preliminary test results where the significant role of the relationship between the trajectory of motion and the texture mesh was demonstrated.

Enhanced X-ray Emissions Arising from High Pulse Repetition Frequency Ultrashort Pulse Laser Materials Processing

The ongoing trend in the development of powerful ultrashort pulse lasers has attracted increasing attention for this technology to be applied in large-scale surface engineering and modern microfabrication. However, the emission of undesired X-ray photon radiation was recently reported even for industrially relevant laser irradiation regimes, causing serious health risks for laser operators. In the meantime, more than twenty influencing factors have been identified with substantial effects on X-ray photon emission released by ultrashort pulse laser processes. The presented study on enhanced X-ray emission arising from high pulse repetition frequency ultrashort pulse laser processing provides new insights into the interrelation of the highest-contributing parameters. It is verified by the example of AISI 304 substrates that X-ray photon emission can considerably exceed the legal dose rate limit when ultrashort laser pulses with peak intensities below 1 × 10¹³ W/cm² irradiate at a 0.5 MHz pulse repetition frequency. The peak intensity threshold value for X-ray emissions decreases with larger laser spot sizes and longer pulse durations. Another key finding of this study is that the suction flow conditions in the laser processing area can affect the released X-ray emission dose rate. The presented results support the development of effective X-ray protection strategies for safe and risk-free ultrashort pulse laser operation in industrial and academic research applications.

A review of advances in tribology in 2020–2021

Around 1,000 peer-reviewed papers were selected from 3,450 articles published during 2020–2021, and reviewed as the representative advances in tribology research worldwide. The survey highlights the development in lubrication, wear and surface engineering, biotribology, high temperature tribology, and computational tribology, providing a show window of the achievements of recent fundamental and application researches in the field of tribology.

Ten Open Questions about Laser-Induced Periodic Surface Structures

Laser-induced periodic surface structures (LIPSS) are a simple and robust route for the nanostructuring of solids that can create various surface functionalities featuring applications in optics, medicine, tribology, energy technologies, etc. While the current laser technologies already allow surface processing rates at the level of m2/min, industrial applications of LIPSS are sometimes hampered by the complex interplay between the nanoscale surface topography and the specific surface chemistry, as well as by limitations in controlling the processing of LIPSS and in the long-term stability of the created surface functions. This Perspective article aims to identify some open questions about LIPSS, discusses the pending technological limitations, and sketches the current state of theoretical modelling. Hereby, we intend to stimulate further research and developments in the field of LIPSS for overcoming these limitations and for supporting the transfer of the LIPSS technology into industry.

LIPSS-based functional surfaces produced by multi-beam nanostructuring with 2601 beams and real-time thermal processes measurement

A unique combination of the ultrashort high-energy pulsed laser system with exceptional beam quality and a novel Diffractive Optical Element (DOE) enables simultaneous production of 2601 spots organized in the square-shaped 1 × 1 mm matrix in less than 0.01 ms. By adjusting the laser and processing parameters each spot can contain Laser Induced Periodic Surface Structures (LIPSS, ripples), including high-spatial frequency LIPSS (HFSL) and low-spatial frequency LIPSS (LSFL). DOE placed before galvanometric scanner allows easy integration and stitching of the pattern over larger areas. In addition, the LIPSS formation was monitored for the first time using fast infrared radiometry for verification of real-time quality control possibilities. During the LIPSS fabrication, solidification plateaus were observed after each laser pulse, which enables process control by monitoring heat accumulation or plateau length using a new signal derivation approach. Analysis of solidification plateaus after each laser pulse enabled dynamic calibration of the measurement. Heat accumulation temperatures from 200 to 1000 °C were observed from measurement and compared to the theoretical model. The temperature measurements revealed interesting changes in the physics of the laser ablation process. Moreover, the highest throughput on the area of 40 × 40 mm reached 1910 cm²/min, which is the highest demonstrated throughput of LIPSS nanostructuring, to the best of our knowledge. Thus, showing great potential for the efficient production of LIPSS-based functional surfaces which can be used to improve surface mechanical, biological or optical properties.

High-power modelocked thin-disk oscillators as potential technology for high-rate material processing

High average power femtosecond lasers have made spectacular progress in the last decades - moving from laboratory-based systems with maximum average powers of tens of watts to kilowatt-class mature industrial systems in a short time. The availability of such systems opens new possibilities in many fields; one of the most prominent ones that have driven many of these technological advances is precise high-speed material processing, where ultrashort pulses have long been recognized to provide highest precision processing of virtually any material, and high average power extends these capabilities to highest processing rates. Here, we focus our attention on one high-average power technology with large unexplored potential for this specific application: directly modelocked multi-MHz repetition frequency high-power thin-disk oscillators. We review their latest state-of-the-art and discuss future directions and challenges, specifically with this application field in mind.

Study on X-ray Emission Using Ultrashort Pulsed Lasers in Materials Processing

The interaction of ultrashort pulsed laser radiation with intensities of 10¹³ W cm⁻² and above with materials often results in an unexpected high X-ray photon flux. It has been shown so far, on the one hand, that X-ray photon emissions increase proportionally with higher laser power and the accumulated X-ray dose rates can cause serious health risks for the laser operators. On the other hand, there is clear evidence that little variations of the operational conditions can considerably affect the spectral X-ray photon flux and X-ray emissions dose. In order to enhance the knowledge in this field, four ultrashort pulse laser systems for providing different complementary beam characteristics were employed in this study on laser-induced X-ray emissions, including peak intensities between 8 × 10¹² W∙cm⁻² < I₀ < 5.2 × 10¹⁶ W∙cm⁻², up to 72.2 W average laser power as well as burst/bi-burst processing mode. By the example of AISI 304 stainless steel, it was verified that X-ray emission dose rates as high as H˙′ (0.07) > 45 mSv h⁻¹ can be produced when low-intensity ultrashort pulses irradiate at a small 1 µm intra-line pulse distance during laser beam scanning and megahertz pulse repetition frequencies. For burst and bi-burst pulses, the second intra-burst pulse was found to significantly enhance the X-ray emission potentially induced by laser pulse and plasma interaction.

Review on Experimental and Theoretical Investigations of Ultra-Short Pulsed Laser Ablation of Metals with Burst Pulses

Laser processing with ultra-short double pulses has gained attraction since the beginning of the 2000s. In the last decade, pulse bursts consisting of multiple pulses with a delay of several 10 ns and less found their way into the area of micromachining of metals, opening up completely new process regimes and allowing an increase in the structuring rates and surface quality of machined samples. Several physical effects such as shielding or re-deposition of material have led to a new understanding of the related machining strategies and processing regimes. Results of both experimental and numerical investigations are placed into context for different time scales during laser processing. This review is dedicated to the fundamental physical phenomena taking place during burst processing and their respective effects on machining results of metals in the ultra-short pulse regime for delays ranging from several 100 fs to several microseconds. Furthermore, technical applications based on these effects are reviewed.

Laser Superficial Fusion of Gold Nanoparticles with PEEK Polymer for Cardiovascular Application

This paper analyses the possibility of obtaining surface-infused nano gold particles with the polyether ether ketone (PEEK) using picosecond laser treatment. To fuse particles into polymer, the raw surface of PEEK was sputtered with 99.99% Au and micromachined by an A-355 laser device for gold particle size reduction. Biomimetic pattern and parameters optimization were key properties of the design for biomedical application. The structures were investigated by employing surface topography in the presence of micron and sub-micron features. The energy of the laser beam stating the presence of polymer bond thermalisation with remelting due to high temperature was also taken into the account. The process was suited to avoid intensive surface modification that could compromise the mechanical properties of fragile cardiovascular devices. The initial material analysis was conducted by power–depth dependence using confocal microscopy. The evaluation of gold particle size reduction was performed with scanning electron microscopy (SEM), secondary electron (SE) and quadrant backscatter electron detector (QBSD) and energy dispersive spectroscopy (EDS) analysis. The visibility of the constituted coating was checked by a commercial grade X-ray that is commonly used in hospitals. Attempts to reduce deposited gold coating to the size of Au nanoparticles (Au NPs) and to fuse them into the groove using a laser beam have been successfully completed. The relationship between the laser power and the characteristics of the particles remaining in the laser irradiation area has been established. A significant increase in quantity was achieved using laser power with a minimum power of 15 mW. The obtained results allowed for the continuation of the pilot study for augmented research and material properties analysis.

Quo Vadis LIPSS?-Recent and Future Trends on Laser-Induced Periodic Surface Structures

Nanotechnology and lasers are among the most successful and active fields of research and technology that have boomed during the past two decades. Many improvements are based on the controlled manufacturing of nanostructures that enable tailored material functionalization for a wide range of industrial applications, electronics, medicine, etc., and have already found entry into our daily life. One appealing approach for manufacturing such nanostructures in a flexible, robust, rapid, and contactless one-step process is based on the generation of laser-induced periodic surface structures (LIPSS). This Perspective article analyzes the footprint of the research area of LIPSS on the basis of a detailed literature search, provides a brief overview on its current trends, describes the European funding strategies within the Horizon 2020 programme, and outlines promising future directions.