Disturbance of material removal in laser-chemical machining by emerging gas

Mehrafsun, Salar; Vollertsen, Frank

doi:10.1016/j.cirp.2013.03.030

Cited by 19 publications

(31 citation statements)

References 5 publications

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“…Within this boiling regime a combined unstable vapor film with partial-nucleate boiling can be formed [20]. This leads to a decreased contact between the heated surface and the liquid solution and provides the evidence of the shielding model [9] that described the effect of an attached gas bubble on the quality of laser chemical machining of metals.…”

Section: Limit Temperatures Of Laser Chemical Removalmentioning

confidence: 99%

“…Thereby, the boiling temperature of the used phosphoric acid (T Boiling = 104˚C) can be achieved at laser powers of about 1 W. Thus, higher laser powers are not recommended as the electrolyte boiling is assumed to affect the quality of LCM because of occurring gas bubble formation [9]. …”

Section: Influence Of Laser Powermentioning

confidence: 99%

“…At high laser intensities an electrolyte boiling can occur resulting on the formation of vapor gas bubble. Among others, Mehrafsun et al [9] and Yavas et al [12] have reported that the formed bubbles result in removal disturbances that impede the controllability of the LCM process. Therefore, it is recommended to avoid electrolyte boiling.…”

Section: Process Fundamentalsmentioning

confidence: 99%

“…As Laser chemical machining is mainly a temperature-driven process, it was experimentally demonstrated that occurring disturbances are strongly related to the electrolyte boiling and the ensuing gas bubble formation [9] as well as to the electrolyte-metal combination [10]. Nevertheless, it is still a lack of knowledge about the direct correlation between the laser-induced temperatures and the resulting removal geometry.…”

Section: Introductionmentioning

confidence: 99%

“…However, the dynamics of the laser light absorption, heat, chemical reactions, hydrodynamics and transport phenomena causes within a certain range of parameters a disturbance of material removal [9]. As Laser chemical machining is mainly a temperature-driven process, it was experimentally demonstrated that occurring disturbances are strongly related to the electrolyte boiling and the ensuing gas bubble formation [9] as well as to the electrolyte-metal combination [10].…”

Section: Introductionmentioning

confidence: 99%

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Thermal Analysis of Laser Chemical Machining: Part I: Static Irradiation

Messaoudi¹,

Eckert²,

Vollertsen³

2017

MSA

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The laser chemical machining is a non-conventional substractive processing method. It is based on the laser-activation of a material dissolution of metals in electrolyte ambient via local-induced temperature gradients and allows a gentle and smooth processing of especially temperature-sensitive metals. However, the material removal is characterized by a narrow process window and is restricted by occurring disturbances, which are supposed to be related to the localized electrolyte boiling. In order to control the removal quality and avoid disturbances, the correlation between the laser-induced temperatures and the resulting removal geometry has to be better understood. In this work an analytical modeling of the laser-induced temperatures at the surface of titanium based on a Green-function approach is presented. The main influencing factors (laser, electrolyte, material) as well as possible heat transfer into the electrolyte are included and discussed. To verify the calculated temperatures, single spot experiments are performed and characterized for titanium in phosphoric acid solution within laser irradiation of 1 s. The correlation between the temperature distribution and the resulting removal geometry is investigated based on a spatial superposition. Thereby, the bottom limit temperature is found to range between 63˚C and 70˚C whereas the upper limit is related to the nucleate boiling regime. Based on the performed correlation an indicator is identified to predict the ruling removal regime and thereby to reduce the experimental expenditure.

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Section: Limit Temperatures Of Laser Chemical Removalmentioning

confidence: 99%

Section: Influence Of Laser Powermentioning

confidence: 99%

Section: Process Fundamentalsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Thermal Analysis of Laser Chemical Machining: Part I: Static Irradiation

Messaoudi¹,

Eckert²,

Vollertsen³

2017

MSA

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Tooling

Vollertsen

Seven

Messaoudi

et al. 2019

Lecture Notes in Production Engineering

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Micro metal parts are usually produced in large lot sizes at high production rates. In order to achieve sufficient product quality, excessive tool wear has to be avoided. In the micro range, so-called scaling effects and their influence on tool wear in micro forming have not been investigated so far. For the investigation, tests in micro deep drawing were carried out with metal sheets (s < 50 μm) of pure aluminum Al99.5, a copper alloy E-Cu58 and stainless steel 1.4301. The failure mechanisms of the micro cups produced were identified as bottom fracture and cup wall damage, and tool wear was measured and characterized with optical measurements and EDX analyses. Moreover, micro cups can be produced by DLC-and PVD-coated tools in a dry forming process. To investigate the wear behavior in a continuous process, a forming tool was developed with an integrated blanking and deep drawing die. The tool wear was measured optically, and the wear mechanisms could be identified in a combined micro and deep drawing process. As a result, the tool could be modified by a manufacturing in selective laser melting and the tool life increased by 290%. Furthermore, a method for tool wear examination in long-term tests was developed. In lateral micro upsetting, the tool wear history can be examined by analyzing the formed product. Several tool materials and coatings were tested with up to 500,000 strokes.

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Machining, Joining and Modifications of Advanced Materials

Öchsner¹,

Altenbach²

2016

Advanced Structured Materials

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Disturbance of material removal in laser-chemical machining by emerging gas

Cited by 19 publications

References 5 publications

Thermal Analysis of Laser Chemical Machining: Part I: Static Irradiation

Thermal Analysis of Laser Chemical Machining: Part I: Static Irradiation

Tooling

Machining, Joining and Modifications of Advanced Materials

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