Laser-Assisted Machining: Processes and Applications

Cover
Title Page
Copyright Page
Dedication
Contents
Preface
Acknowledgments
Chapter 1 Introduction to Laser-Assisted Machining
	1.1 Introduction
	1.2 Laser-Assisted Machining—Overview
	1.3 Machining of Advanced Materials
		1.3.1 Titanium Alloys
		1.3.2 Nickel-Based Alloys
		1.3.3 Ceramics
		1.3.4 Ferrous Alloys
		1.3.5 Composites
	1.4 Machining Requirements
	1.5 Tools to be Used
	1.6 Lasers for Machining
	1.7 Machining Requirements
	1.8 Conclusion
	References
Chapter 2 Laser Welding in Manufacturing Applications
	2.1 Introduction
	2.2 Research Advancements in Laser Welding
		2.2.1 Process Variables in Advanced Laser Welding Techniques
	2.3 Types of Laser Welding
		2.3.1 Combining Laser Welding with Different Weld Methods
	2.4 Advantages of Laser Welding Processes
	2.5 Conclusion
	2.6 Future Scope of Work
	References
Chapter 3 Laser-Assisted Machining for Advanced Materials
	3.1 Introduction
	3.2 Laser-Assisted Machining Technology
	3.3 Laser-Assisted Machining of Advanced Materials
		3.3.1 Nickel-Based Superalloy
		3.3.2 Titanium and Its Alloys
		3.3.3 Metal Matrix Composites
		3.3.4 Composite Materials
		3.3.5 Ceramics
		3.3.6 Nickel Alloys
		3.3.7 Ferrous Alloys
	3.4 Laser Applications for Machining
	3.5 Conclusions
	3.6 Future Scope of LAM
	References
Chapter 4 Optimization of Laser Cutting Parameters Using the Taguchi Approach
	4.1 Introduction
	4.2 Literature Survey
	4.3 Methodology
	4.4 Experimental Study
	4.5 SN vs. Responses
	4.6 Mean Plot
	4.7 Discussion
	4.8 Conclusion
	References
Chapter 5 Laser-Assisted Micromilling (LAMM): Process and Applications
	5.1 Introduction
	5.2 Laser-Assisted Micromilling Process
		5.2.1 Micromilling Process
		5.2.2 Laser-Assisted Micromilling (LAMM)
			5.2.2.1 Construction and Working of LAMM
		5.2.3 Type of Lasers Used in LAMM
			5.2.3.1 Nd:YAG Laser
			5.2.3.2 CO2 Laser in LAMM
		5.2.4 Thermal Analysis
			5.2.4.1 Temperature Increases due to Laser Heating
			5.2.4.2 Temperature Increases due to Plastic Deformation
	5.3 Effect of Parameters on LAMM
		5.3.1 Effect of Cutting Speed on LAMM
		5.3.2 Effect of Chip Thickness on LAMM
	5.4 Applications of Laser-Assisted Micromilling (LAMM)
	References
Chapter 6 Removing Algae and Moss Growth on Compressed Stabilized Earth Block Wall Surface by Laser Cleaning
	6.1 Introduction
	6.2 Background
	6.3 Research Objectives
	6.4 Research Gap
	6.5 Literature Review
		6.5.1 The Use of Compressed Stabilized Earth Blocks
	6.6 Algae and Moss Growth on CSEB Wall Surfaces
		6.6.1 Algae Identification on Compressed Stabilized Earth Block Wall Surface
		6.6.2 Moss Growth on Compressed Stabilized Earth Block Wall Surface
		6.6.3 Influence of Algae and Moss Growth Contamination on Compressed Stabilized Earth Block Wall Surface Properties
	6.7 Laser Cleaning Technology
	6.8 Dry Laser Cleaning Method
	6.9 Liquid-Based Laser Cleaning
	6.10 Impact of Laser Cleaning on the Surrounding Environment
	6.11 Practical Applications
		Future Study
		Results and Discussion
	Summary
	Conclusion
	References
Chapter 7 A Review of the Effects of Laser Cleaning on the Development of Corrosion and the Removal of Rust in Steel Bridges in Marine Environments
	7.1 Introduction
	7.2 Corrosion Development
	7.3 Rust Removal from Steel Bridges in Marine Climates
	7.4 Effectiveness of Laser Cleaning in Rust Removal from Steel Bridges in Marine Climates
	7.5 Background and Significance of Corrosion in Steel Bridges under Marine Climate
		7.5.1 Background
		7.5.2 Significance
	7.6 Overview of Current Rust Removal Methods
		7.6.1 Mechanical Rust Removal Methods
		7.6.2 Chemical Rust Removal Methods
		7.6.3 Electrochemical Rust Removal Methods
	7.7 The Potential of Laser Cleaning as an Alternative Method
	7.8 History of Laser Cleaning
	7.9 Benefits of Laser Cleaning
	7.10 Applications of Laser Cleaning
	7.11 Review of Literature
	7.12 Research Gaps
	7.13 Research Objectives
	7.14 Corrosion Development in Steel Bridges Under Marine Climate
	7.15 Corrosion of Steel Bridges in Marine Climates
	7.16 Preventative Measures
	7.17 Factors Influencing Corrosion Development
	7.18 Mechanisms of Corrosion in Steel Structures Exposed to the Marine Environment
	7.19 The Marine Environment
	7.20 Types of Corrosion
	7.21 Mitigation of Corrosion
	7.22 Case Studies of Corrosion in Steel Bridges Under Marine Climate
	7.23 Rust Removal Methods for Steel Bridges
	7.24 Traditional Methods: Mechanical, Chemical, and Abrasive Methods
		7.24.1 Mechanical Rust Removal
		7.24.2 Chemical Rust Removal
		7.24.3 Abrasive Rust Removal
	7.25 Laser Cleaning as a Potential Rust Removal Method
		7.25.1 Principles of Laser Cleaning
		7.25.2 Advantages of Laser Cleaning
		7.25.3 Disadvantages of Laser Cleaning
		7.25.4 Steps Involved in Laser Cleaning
		7.25.5 Advantages and Disadvantages of Laser Cleaning Compared with Traditional Methods
	7.26 Challenges and Future Research Directions
		7.26.1 Challenges in Applying Laser Cleaning for Rust Removal in Steel Bridges
	7.27 The Effects of the Marine Environment on Laser Cleaning
	7.28 Safety Considerations
	7.29 Difficulties of Working in a Confined Space
	7.30 Potential Benefits of Laser Cleaning
	7.31 Future Advancements
	7.32 Future Research Directions to Optimize Laser Cleaning Applications for Steel Bridges Under Marine Climate
	7.33 Conclusion
	7.34 Summary of Key Findings
	7.35 Implications and Future Directions for Research and Practice
	References
Chapter 8 Laser-Assisted Machining: Its Capability and Future
	8.1 Introduction
	8.2 Laser-Assisted Machining
	8.3 LAM of Ceramics
	8.4 LAM of Advanced Materials
	8.5 LAM of Metal Matrix Composites
	8.6 Laser-Assisted Micromilling and Macromilling
	8.7 Future Prospect
	References
Chapter 9 A Review of the Applications of the Laser Crack Measurement for White Topping Road
	9.1 Introduction
	9.2 Background
	9.3 Laser Crack Measurement System
		9.3.1 Limitations
		9.3.2 Merits
		9.3.3 Demerits
		9.3.4 Crack Types
		9.3.5 Detection and Classification Technique
		9.3.6 Components, Types, and Subfields of the Laser Crack Measurement System
		9.3.7 Components
		9.3.8 Types
		9.3.9 Subfields
	9.4 Research Objectives
	9.5 Research Gap
	9.6 Literature Review
	9.7 Practical Applications
	9.8 Different Types of Laser Crack Measurement Systems
	9.9 Performance
	9.10 System Overview
	9.11 Overview of Laser Crack Measurement System in White Topping Road and Its Subfields
	9.12 Experimental Process
		9.12.1 The Flowchart of the Method of Detection of Cracks in White Topping Surface Using the Laser Crack Measurement System
	9.13 Generation of the Pavement Crack Skeleton Using the Laser Crack Measurement System
		9.13.1 Calculation of Pavement Crack-Shape Parameters Using the Laser Crack Measurement System
	9.14 Existing System Works
	9.15 Future Study
	9.16 Results and Discussion
	9.17 Summary
	9.18 Conclusion
	References
	10 Characterization of Tensile and Impact Properties of Fabricated AlSi10Mg by Selective Laser Melting Technique
		10.1 Introduction
		10.2 Material and Methods
			10.2.1 Physical and Chemical Properties of AlSi10Mg Powder
			10.2.2 Machine Specification
			10.2.3 Process Parameters
			10.2.4 Process of Manufacturing in SLS
		10.3 Result and Discussion
			10.3.1 Tensile Strength
			10.3.2 Charpy Testing
			10.3.3 Microstructure and Microhardness
			10.3.4 Fractography of the Tensile Sample
		10.4 Conclusion
		References
Chapter 11 The Developments and Retrospect of Water–Laser Machining Technology: An Overview
	11.1 Introduction
	11.2 Historical Background
	11.3 Waterjet-Guided Laser Machining Process
		11.3.1 Working Principle of the Waterjet-Guided Laser Machining Process
		11.3.2 Advantages of the Waterjet-Guided Laser Machining Process
		11.3.3 Applications of the Waterjet-Guided Laser
		11.3.4 Review of Literature on Waterjet-Guided Laser Machining Process
	11.4 Waterjet-Assisted Laser Machining Process
		11.4.1 Working Principle of the Waterjet-Assisted Laser Machining Process
		11.4.2 Advantages of the Waterjet-Assisted Laser Machining Process
		11.4.3 Disadvantages of the Waterjet-Assisted Laser Machining Process
		11.4.4 Applications of the Waterjet-Assisted Laser Machining Process
		11.4.5 Review of the Literature on Waterjet-Assisted Laser Machining Process
	11.5 The Underwater Laser Machining Process
		11.5.1 Working Principle of the Underwater Laser Machining Process
		11.5.2 Advantages of the Underwater Laser Machining Process
		11.5.3 Applications of the Underwater Laser Machining Process
		11.5.4 Review of the Literature on Underwater Laser Machining Process
	11.6 Research Summary on the Water–Laser Machining Process
	11.7 Conclusion
	References
Chapter 12 Laser Welding of Aluminum Alloys
	12.1 Introduction
		12.1.1 Basic Description of Al Alloys
		12.1.2 Why Laser Welding?
		12.1.3 Problems Faced by Al Alloys During Laser Welding
		12.1.4 Examples of Dissimilar Material Laser Welding and Their Characteristics
		12.1.5 Aims of the Book Chapter
	12.2 Laser Welding Processes of Wrought Aluminum Alloys
	12.3 Process Variables
	12.4 Microstructures of Different Laser-Welded Al Alloys
	12.5 Mechanical Properties of Laser-Welded Al Alloys
	12.6 Defects and Remedies
	12.7 Conclusion
	References
Chapter 13 Laser-Assisted Grinding and Milling
	13.1 Introduction
	13.2 High-Strength Materials
		13.2.1 Superalloys
		13.2.2 Ceramic Materials
		13.2.3 Nickel Based Alloys
	13.3 Laser-Assisted Machining
	13.4 Laser-Assisted Grinding
		13.4.1 The Mechanism of LAG in Ceramic Material
	13.5 Laser-Induced Wet Grinding
	13.6 Process Parameters in LAG
		13.6.1 Effect of Laser Scan Speed and Laser Line Span on LAG
		13.6.2 Effect of Laser Input Energy on LAG
		13.6.3 Microstructural Variations During LAM
		13.6.4 The Heat-Affected Zone (HAZ) and Its Effect on LAM
	13.7 Modes of LAG
	13.8 Laser-Assisted Milling
	13.9 Conclusion
	References
Chapter 14 Trends in Laser-Assisted Hybrid Machining to Enhance the Performance Quality of Electrical Discharge Machining Process: Opportunities and Challenges
	14.1 Introduction
	14.2 Research Trends in Laser-Assisted Machining
		14.2.1 Laser Dr illing and High-Speed EDM
		14.2.2 Laser-Assisted Premachining for Making Holes Using Micro-EDM
		14.2.3 Production of Electrical Discharge Machining Electrodes Using Laser-Assisted Machining
			14.2.3.1 Laser Cladding
			14.2.3.2 Selective Laser Sintering
			14.2.3.3 Direct Metal Laser Sintering for EDM Electrodes
	14.3 Optimization Techniques for Improving the Performance of EDM Electrodes
	14.4 Conclusion
	References
Chapter 15 Laser Welding of Thin Ferrous Sheets with Ferrous and Non-Ferrous Sheets
	15.1 Introduction
	15.2 Autogenous Laser Welding of Similar and Different Ferrous Alloys
		15.2.1 Stainless Steel
		15.2.2 Galvanized Steels
		15.2.3 Dissimilar Ferrous Materials
	15.3 Laser Welding of Different Ferrous and Non-Ferrous Materials
		15.3.1 Autogenous Dissimilar Welding
		15.3.2 Dissimilar Welding with Filler Material
	15.4 Conclusions
	15.5 Future Scope
	References
Chapter 16 Laser Cutting, Drilling, and Piercing
	16.1 Introduction to Laser Beam Machining
		16.1.1 Production of Lasers
		16.1.2 Laser Beam Machining Main Parts
		16.1.3 Applications of Laser Beam
		16.1.4 Different Types of Lasers
	16.2 Laser Beam Drilling
		16.2.1 Laser Beam Drilling Involves a Variety of Drilling Techniques
		16.2.2 Drilling Techniques
			16.2.2.1 Percussion Laser Beam Drilling
			16.2.2.2 Trepanning
			16.2.2.3 Helical Laser Drilling
			16.2.2.4 Multi-Laser Beam Drilling
			16.2.2.5 Mask Drilling
		16.2.3 Laser Beam Drilling Equations
		16.2.4 How Does Light Work to Drill a Hole?
	16.3 Laser Beam Piercing
		16.3.1 Types of Laser Beam Piercing
	16.4 Laser Beam Cutting
		16.4.1 Types of Laser Beam Cutting
	16.5 Laser Beam Welding
	16.6 Laser Beam Marking
	16.7 Laser Beam Milling
	References
Chapter 17 Femtosecond Laser Machining
	17.1 Introduction
	17.2 Literature Review
	17.3 Fundamental Principles of Femtosecond Laser Micromachining
		17.3.1 Definition and Explanation of Femtosecond Laser Micromachining
		17.3.2 Advantages and Limitations of Femtosecond Laser Micromachining Compared with Other Micromachining Techniques
		17.3.3 Limitations
		17.3.4 Applications of Femtosecond Laser Micromachining in Various Industries
	17.4 Femtosecond Laser Principles
		17.4.1 Femtosecond Laser Pulse Generation
		17.4.2 Laser–Matter Interaction Mechanism in Femtosecond Laser Micromachining
		17.4.3 Laser Parameters That Affect the Micromachining Process
	17.5 Material Interaction and Microfabrication
		17.5.1 Effects of Laser Parameters on the Micromachined Material
		17.5.2 Explanation of the Mechanism of Material Ablation in Femtosecond Laser Micromachining
		17.5.3 Analysis of the Factors Affecting the Material Removal Rate
		17.5.4 Discussion of the Microfabrication Capabilities of Femtosecond Laser Micromachining
	17.6 Femtosecond Laser Micromachining Techniques
		17.6.1 Advantages and Disadvantages of Each Technique
		17.6.2 Comparison of the Results Obtained from Different Micromachining Techniques
	17.7 Femtosecond Laser Micromachining Applications
		17.7.1 Applications of Femtosecond Laser Micromachining in the Field of Microelectronics
		17.7.2 Applications of Femtosecond Laser Micromachining in the Medical and Biological Fields
		17.7.3 Applications of Femtosecond Laser Micromachining in the Field of Materials Science
	17.8 Conclusion
	17.9 Future Potential and Limitations of Femtosecond Laser Micromachining
	17.10 Suggestions for Further Research in the Field of Femtosecond Laser Micromachining
	References
Chapter 18 Fundamentals of Laser Welding
	18.1 Introduction
		18.1.1 Definition
		18.1.2 Advantages of Laser Welding
		18.1.3 Applications of Laser Welding
	18.2 Process of Laser Welding
		18.2.1 Overview of the Laser Welding Process
		18.2.2 Types of Lasers Used in Laser Welding
		18.2.3 Welding Techniques and Parameters
	18.3 Materials and Joint Designs for Laser Welding
		18.3.1 Suitable Materials for Laser Welding
		18.3.2 Joint Design Considerations
		18.3.3 Welding Quality and Inspection Methods
	18.4 Equipment and Safety in Laser Welding
		18.4.1 Laser Welding Equipment
		18.4.2 Safety Considerations
		18.4.3 Personal Protective Equipment
	18.5 Conclusions
		18.5.1 Summary of Key Points
		18.5.2 Future Developments in Laser Welding
		18.5.3 Final Thoughts and Recommendations
	References
Chapter 19 High-Power Laser in Material Processing Applications
	19.1 Introduction
	19.2 Literature Review
	19.3 The Use of High-Power Diode Lasers in the Industry for Material Processing
		19.3.1 Diode Laser Technology
		19.3.2 Diode Laser System with a High-Power Output
		19.3.3 Industrial Diode Laser Application
	19.4 Transversal Flow with High-Power CW-CO2 Laser
		19.4.1 Laser Power Scaling in TFTE Laser
		19.4.2 Laser System
		19.4.3 Programmable SMPS Design
	19.5 Characteristics of the Optical and Thermal Performance of the SLM Used in Material Processing Applications
		19.5.1 Experimental Details
		19.5.2 Results
	19.6 Recent Development in High-Power Lasers
		19.6.1 Nd:YAG Lasers
		19.6.2 High-Power Thin Disc Laser
		19.6.3 Fiber Laser
		19.6.4 Ultrafast Laser
	19.7 Laser–Material Interaction
		19.7.1 Fundamental Laser Radiation Absorption Mechanism in Materials
		19.7.2 Beam Spatial Properties on Laser–Material Interaction
		19.7.3 Influence of the Laser Pulse Duration on Laser–Material Interaction
		19.7.4 Material Removal Mechanism During Laser–Material Interaction
	19.8 Conclusions
	References
Chapter 20 Hybrid Laser Electrochemical Micromachining
	20.1 Introduction
		20.1.1 Definition of Hybrid Laser Electrochemical Micromachining
		20.1.2 Significance of Hybrid Laser Electrochemical Micromachining
		20.1.3 Pros and Cons over Other Micromachining Processes
	20.2 Literature Review
	20.3 Principles of Laser and Electrochemical Micromachining
		20.3.1 Energy and Material Transport During the Process
	20.4 Laser Parameters
		20.4.1 Electrochemical Parameters
		20.4.2 Microelectronics, Microfluidics, and Biomedical Applications
	20.5 Experimental Investigation of a Tool-Based Hybrid Laser Electrochemical Micromachining (HLECM) Process
		20.5.1 Hybrid Tooling Concept for Coaxial and Concurrent Applications
	20.6 Technical Challenges and Limitations
		20.6.1 Challenges in Process Control and Monitoring
	20.7 Conclusions
		20.7.1 Current and Future Aspects
		20.7.2 Development in the Area of Hybrid Laser Electrochemical Micromachining
	References
Chapter 21 Introduction to Solid-State Lasers
	21.1 Introduction
	21.2 Innovations on Solid-State Lasers
		21.2.1 Atomic Transitions and Radiation Exchange Energy
		21.2.2 Absorption and Optical Gain
		21.2.3 Optical Pumping System
		21.2.4 Energy Storage
		21.2.5 Wavelength Tuning
		21.2.6 Pulse Generation
	21.3 Solid-State Laser Materials Property
		21.3.1 Host Material
	21.4 Types of Solid-State Laser
		21.4.1 Ruby Laser
		21.4.2 Nd:YAG Laser
		21.4.3 Ti:Sapphire Laser
	21.5 Comparison of SSLs with Other Lasers
	21.6 Application of Solid-State Lasers
	21.7 Future Scope of Solid-State Lasers
	21.8 Summary
	References
Chapter 22 Laser Micro- and Nanoprocessing
	22.1 Introduction
		22.1.1 Definition
	22.2 Literature Review
	22.3 Fundamental Aspects
	22.4 Laser Processing
	22.5 Micromachining
	22.6 Nanomachining
	22.7 Drilling and Cutting
	22.8 Manufacture of Microdevices and Systems
	22.9 Synthesis of Advanced Materials
	22.10 Nano- and Microparticles
	22.11 Applications
	22.12 Photochemistry
	22.13 Glass Processing
	22.14 Ceramic Processing
	22.15 Conclusion
	References
Chapter 23 Waterjet-Guided Laser Cutting Technology
	23.1 Introduction
	23.2 Literature Review
	23.3 Waterjet Machining
		23.3.1 Applications of WJM
		23.3.2 Advantages
		23.3.3 Disadvantages
	23.4 Laser Beam Machining
		23.4.1 Advantages
		23.4.2 Disadvantages
		23.4.3 Applications
	23.5 Water-Guided Laser Jet Machining
		23.5.1 Working Principle
		23.5.2 Metal Removal Rate
		23.5.3 Process Parameters
		23.5.4 Advantages of Water-Guided Laser Machining
		23.5.5 Disadvantages of Water-Guided Laser Machining
		23.5.6 Applications
	23.6 Conclusion
	References
Chapter 24 Fundamentals of Laser Machining
	24.1 Introduction
	24.2 Lasing Action and Population Inversion
		24.2.1 Absorption
		24.2.2 Spontaneous Emission
		24.2.3 Stimulated or Induced Emission
	24.3 Methods to Achieve Population Inversion
		24.3.1 Optical Pumping
		24.3.2 Direct Electron Excitation (Argon Laser)
		24.3.3 Inelastic Atom–Atom Collisions (Helium–Neon Laser)
	24.4 Types of Lasers
		24.4.1 Solid-State Lasers
		24.4.2 CO2 Gas Laser
	24.5 Applications of LBM
		24.5.1 Laser Drilling
		24.5.2 Laser Cutting
		24.5.3 Laser Welding
		24.5.4 Laser Heat Treatment
		24.5.5 Laser Cladding
		24.5.6 Laser Scribing
		24.5.7 Controlled Fracture
		24.5.8 Laser Trimming
	24.6 Advantages of LBM
	24.7 Disadvantages of LBM
	24.8 Comparison between EBM and LBM
	References
Chapter 25 Opportunities and Challenges in Laser Bending
	25.1 Introduction
	25.2 Laser Straightening
	25.3 Laser Adjustments
	25.4 Laser Bending of Tube
	25.5 Mechanisms
		25.5.1 The Mechanism for Thermal Gradients
		25.5.2 Point-Source Mechanism
		25.5.3 Buckling Mechanism
		25.5.4 Upsetting Mechanism
		25.5.5 Coupling Mechanism
	25.6 Extended Applications
	25.7 Challenges in Laser Bending
	25.8 Laser Bending for Brittle Material
	25.9 Summary
	References
Chapter 26 Laser Cleaning and Its Advancements
	26.1 Introduction
	26.2 Pulsed Laser Cleaning
	26.3 Continuous Wave Laser Cleaning
	26.4 Q-Switched Laser Cleaning
	26.5 Fiber Laser Cleaning
	26.6 CO2 Laser Cleaning
	26.7 Nd:YAG (Neodymium-Doped Yttrium Aluminum Garnet) Laser Cleaning
	26.8 Visual Monitoring Methods
	26.9 Ultraspeed Cleaning Application
	26.10 Challenging Cleaning Applications
	26.11 Laser Cleaning in Medical Applications
	26.12 Summary
	References
Index
EULA