High Throughput Direct Laser Interferential Patterning of Aluminum for Fabrication of Super Hydrophobic Surfaces

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.

The Influence of Adventitious Carbon Groups on the Wetting of Copper: A Study on the Effect of Microstructure on the Static Contact Angle

Tuning of the wetting behavior of metallic surfaces by chemical and topographical modification has become popular in recent years. Still, there is a lack in the understanding of fundamental relations between intrinsic properties of the material and its resulting water contact angle. It is widely accepted in the literature that transitions from a hydrophilic to increasingly hydrophobic behavior upon exposure to ambient conditions happen due to the adsorption of adventitious hydrocarbons. In order to investigate the role of metallic bulk microstructure in the wetting behavior and its transition properties, we created three different grain sizes and deformation states on copper by preparation combined with heat treatment. We found that for freshly prepared surfaces, differences in the wetting behavior show a higher static contact angle for mechanically prepared surfaces with a fine-crystalline deformation layer compared to the electropolished cold-rolled copper sheet and the annealed defect-free coarse-grained surface. Already after five days of storage time, most of this difference vanishes, and all surfaces show a wetting behavior with a contact angle in the range of 97-100° after 30 days. Though long-term wetting behavior seems largely independent of microstructure, correlated XPS measurements showed an increased adsorption of organic contaminants of the mechanically polished surface. Preparation-induced near-surface defects seem to accelerate adsorption, while varying grain size and slight bulk deformation from rolling processes did not show significant effects. Complex relations between the amount of adsorbed carbon and the polarity of the adsorption film were found to depend on the sample age and influence the contact angle.

Utilizing a Diffractive Focus Beam Shaper to Enhance Pattern Uniformity and Process Throughput during Direct Laser Interference Patterning

Uniform periodic microstructure formation over large areas is generally challenging in Direct Laser Interference Patterning (DLIP) due to the Gaussian laser beam intensity distribution inherent to most commercial laser sources. In this work, a diffractive fundamental beam-mode shaper (FBS) element is implemented in a four-beam DLIP optical setup to generate a square-shaped top-hat intensity distribution in the interference volume. The interference patterns produced by a standard configuration and the developed setup are measured and compared. In particular, the impact of both laser intensity distributions on process throughput as well as fill-factor is investigated by measuring the resulting microstructure height with height error over the structured surface. It is demonstrated that by utilizing top-hat-shaped interference patterns, it is possible to produce on average 44.8% deeper structures with up to 60% higher homogeneity at the same throughput. Moreover, the presented approach allows the production of microstructures with comparable height and homogeneity compared to the Gaussian intensity distribution with increased throughput of 53%.

Simultaneous Micro-Structuring and Surface Smoothing of Additive Manufactured Parts Using DLIP Technique and Its Influence on the Wetting Behaviour

It is well known that the surface topography of a part can affect its function as well as its mechanical performance. In this context, we report on the surface modification of additive manufactured components made of Titanium 64 and Scalmalloy^®, using Direct Laser Interference Patterning technique. In our experiments, a nanosecond-pulsed near-infrared laser source with a pulse duration of 10 ns was used. By varying the process parameters, periodic structures with different depths and associated roughness values are produced. Additionally, the influence of the resultant morphological characteristics on the wettability behaviour of the fabricated textures is investigated by means of contact angle measurements. The results demonstrated a reduction of the surface roughness of the additive manufactured parts (in the order of some tens of micrometres) and simultaneously the production of well-defined micro-patterns (in the micrometre range), which allow the wettability of the surfaces from 26° and 16° up to 93° and 131° to be tuned for Titanium 6Al 4V and Al-Mg-Sc (Scalmalloy^®), respectively.

Hydrophobic and Anti-Icing Behavior of UV-Laser-Treated Polyester Resin-Based Gelcoats

Ice accumulation on wind turbine blades due to the impact of supercooled water droplets can be reduced by the application of surfaces with anti-icing properties. Hydrophobic surfaces are considered as a promising solution because of their water repellent behavior. In recent years, short-pulsed laser technologies have been developed as an efficient technique to modify the surface properties of materials. However, the anti-icing properties of such surfaces have not yet been validated. In this work, a hybrid modification of polyester resin-based gelcoats was adopted. Laser patterning (LP) was used to produce periodic surface structures on modified unsaturated polyester resin (UPR) substrates. One of the innovations of this research is the utilization of novel purpose-made chemical modifiers for gelcoats. The implementation of linear polymethylhydrosiloxane (PMHS) as a building block is a key improvement in terms of durability and functionality of the coating, since there is an option of introducing not only groups bonding in the polyester into one molecule, but also groups that increase hydrophobicity. The other novelty is a successfully conducted experiment combining such chemical modification with laser texturization of the surface. The influence of the laser energy, pattern shape, and spatial periods on the topographical characteristics and hydrophobicity as well as the anti-icing properties of the produced surfaces were investigated. To characterize the surface topography of the produced structures, scanning electron microscopy (SEM) and profilometer were utilized. Measurements of the wettability parameters (static contact angle and contact angle hysteresis) on the treated surfaces allowed the identification of the influence of wetting behavior and laser parameters on the investigated materials. Anti-icing properties were characterized by ice adhesion (IA) and freezing delay time (FDT) tests. It was found that hybrid modification of unsaturated polyester resin by chemical modifiers and laser treatment increased the hydrophobic and anti-icing properties of polyester gelcoats.

Development of a Monitoring Strategy for Laser-Textured Metallic Surfaces Using a Diffractive Approach

The current status of research around the world concurs on the powerful influence of micro- and nano-textured surfaces in terms of surface functionalization. In order to characterize the manufactured topographical morphology with regard to the surface quality or homogeneity, major efforts are still required. In this work, an optical approach for the indirect evaluation of the quality and morphology of surface structures manufactured with Direct Laser Interference Patterning (DLIP) is presented. For testing the designed optical configuration, line-like surface patterns are fabricated at a 1064 nm wavelength on stainless steel with a repetitive distance of 4.9 µm, utilizing a two-beam DLIP configuration. Depending on the pulse to pulse overlap and hatch distance, different single and complex pattern geometries are produced, presenting non-homogenous and homogenous surface patterns. The developed optical system permitted the successfully classification of different pattern geometries, in particular, those showing single-scale morphology (high homogeneity). Additionally, the fabricated structures were measured using confocal microscopy method, and the obtained topographies were correlated with the recorded optical images.