Laser Processing: Surface Treatment and Film Deposition

936 Pages·1996·33.989 MB·English

by  W. M. Steen (auth.), J. Mazumder, O. Conde, R. Villar, W. Steen (eds.)

Laser Processing:
Surface Treatment and Film Deposition
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Series E: Applied Sciences· Vol. 307
Laser Processing:
Surface Treatment
and Film Deposition
edited by
J. Mazumder
Department of Mechanical and Industrial Engineering,
University of Illinois,
Urbana-Champaign, IL, U.S.A.
o.
Conde
Department of Physics,
University of Lisbon,
Lisbon, Portugal
R. Villar
Department of Materials Engineering,
Instituto Superior Tecnico,
Lisbon, Portugal
and
w.
Steen
Department of Mechanical Engineering,
University of Liverpool,
Liverpool, UK
Kluwer Academic Publishers
Dordrecht / Boston / London
Published in cooperation with NATO Scientific Affairs Division
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Table of Contents
Introduction ix
Graduate Student's Report xi
Chapter 1. Overview and Fundamentals
Laser Surface Treatment - An overview
(W.M. Steen)
Coupling Mechanisms in Laser Surface Treatment
(H. Hugel, F. Dausinger, W. Bloehs and B. Grunenwald) 21
Non-Equilibrium Synthesis by Laser for Tailored Surfaces
(1. Mazumder) 47
Microstructure and Phase Selection in Rapid Laser Processing
(p. Gilgien and W. Kurz) 77
Solidification of AgCu Alloys at High Growth Rates Produced by Continuous Laser
Melt Quenching
(S.M. Copley, I.A. Todd, M. Yankova and E.Y. Yankov 93
Surface Response Functions Due to Laser Irradiation
(W.W. Duley) 121
Chapter 2. Mathematical Modeling
Modeling in Laser Materials Processing: Melting, Alloying, Cladding
(A. Kar and 1. Mazumder) 129
Scoping Analyses and Limitations of Transport Phenomena Modeling for Laser Sur-
face Modification
(M.M. Chen) 157
The Modelling of Heat, Mass, and Solute Transport in Surface Processing with Laser
Radiation
(N. Pirch, E.W. Kreutz, B. Ollier and X. He) 177
One-Dimensional Thermal Model Including the Dependence of Absorptivity on Tem-
perature Using Hagen-Rubens Equation
(A.M. Deus and R. Vilar) 195
vi
Modeling of Laser Chemical Vapor Deposition of Thin Films
(A. Kar and I. Mazumder) 203
Chapter 3. Laser Alloying
Functionality Gradient Coating Layers Produced by Laser Alloying/Cladding
(I.H. Abboud, D.R.F. West and R.D. Rawlings) 237
Carbide and Boride Laser Alloying of High Speed Steels
(R. Ebner, K. Rabitsch, B. Kriszt and B. Major) 255
Innovative Intennetallic Compounds by Laser Alloying
(I. Smurov and M. Ignatiev) 267
Gas Surface Alloying of Ti6A14V Alloy by Laser
(A. Zambon, E. Ramous, M. Magrini, M. Bianco and C. Rivela) 327
Laser Surface Alloying of Aluminum 2014 Alloy with Molybdenum for Enhanced
Corrosion Resistance
(M.A. McMahon, K.G. Watkins, M.G.S. Ferreira, R.M. Vuar and W.M. Steen) 337
Laser Alloying of Copper and Its Alloys
(S.P. Gadag, R. Galun, A. Weisheit and B.L. Mordike) 359
Chapter 4. Laser Cladding
Laser Cladding of Low Melting Point Alloys
(M. Ellis, D.C. Xiao, W.M. Steen, C. Lee, K.G. Watkins and W.P. Brown) 379
Catchment Efficiency for Novel Nozzle Designs Used in Laser Cladding and Alloying
(S. Carty, I. Owen, W.M. Steen, B. Bastow and I.T. Spencer) 395
Laser Process Adapted Powder Delivery System
(B. Grlinewald, W. Hennig, St. Nowotny, F. Dausinger and H. Hugel) 411
A Simple Correlation Between the Geometry of Laser Cladding Tracks and the Process
Parameters
(R. Cola~o, L. Costa, R. Guerra and R. Vilar) 421
Surface Treatment by Laser Processing and Tribological Application
(A.B. Vannes and I.M. Pelletier) 431
Chapter 5. Surface Treatment
Laser Surface Treatment of Tool Steels
(R. Vilar, R. Cola~o and A. Almeida) 453
vii
Laser Treatment for Adhesive Bonding in Coated Steels
(M. Olfert, W.W. Duley and T. North) 479
Structure-Property Relationship of Ceramic Coatings on Metals Produced by Laser
Processing
(J.Th.M. De Hosson and M. Van Den Burg) 491
Microstructures and Mechanical Properties of Laser Treated Aluminum Alloys
(J.Th.M. De Hosson, L. De Mol Van Otterloo and J. Noordhuis) 511
Real Time Pyrometry in Laser Surface Treatment
(1. Smurov and M. Ignatiev) 529
Microstructure and Properties of AI-Nb Alloys Produced by Laser Surface Treatment
(p. Petrov, R. Vilar and A. Almeida) 565
Laser Surface Melting and Gas-Alloying of Ti-6Al-4V
(J.M. Robinson, R.C. Reed and D.R.F. West) 575
Process Diagrams for Laser Transformation Hardening
(J.C. Ion) 587
The Use of Lasers in the Formation of Vitreous Layers on Surfaces
(KJ. Blair, J.T. Spencer, L. Li and W.M. Steen) 613
Direct Synthesis of Metal Nitride by Laser
(C. Boulmer-Leborgne, A.L. Thomann and J. Hermann) 629
Chapter 6. Laser Thin Film Deposition
Laser Processing of High-Tc Superconductors
(K. Mukherjee, C.W. Chen, J. Yoo, I. Oh and S. Kudapa) 637
Laser Chemical Vapour Deposition of Titanium-Based Hard Coatings
(0. Conde, AJ. Silvestre and M.L. Parames) 665
Laser Chemical Vapor Deposition of Titanium Nitride and Process Diagnostics with
Laser Induced Fluorescence Spectroscopy
(X. Chen, M.N. Azer, K.M. Egland and J. Mazumder) 693
Process Control of Laser Chemical Vapour Deposition of TiC on Tool Steel
CA. Hatziapostolou, I. Zergioti, E. Hontzopoulos, A. Zervaki and G. Haidemenopou-
los) 703
Ultrafine Metal Particles in Polymers and in Vapor Phase Nucleation
(M.S. EI-Shall) 711
Pulsed Laser Deposition of Nbs Te4 Thin Films
(p. Grangeon, H. Sassoli, L. Lambert, M. Autric, Y. Mathey and W. Marine) 727
viii
Chapter 7. Laser Ablation
Thin Film Deposition by Laser Ablation
(W.W. Duley) 739
Laser Ablation and Application to Thin Film Deposition
(A. Catherinot. B. Angleraud, J. Aubreton, C. Champeaux, C. Gennain and C. Girault) 751
Theoretical Description of Laser Ablation
(C. KOmer and H.W. Bergmann) 797
Laser Reactive Ablation: One Step Procedure for the Synthesis and Deposition of
Compound Thin Films
(M. Dinescu, N. Chitica, V.S. Teodorescu, A. Lita, A. Luches, M. Martino, A. Perrone
and M. Gartner) 809
Pulsed Laser Ablation of Copper
(R. Jordan, D. Cole, J.G. Lunney, K. Mackay and D. Givord) 823
Chapter 8. Application to Industry
Adaptive Beam Delivery for CO2 Laser Material Processing
(M. Geiger, N. Neubauer, P. Hoffmann and J. Hutfless) 831
Laser Beam Welding Fume Propagation and Seam Properties
(M. Dahmen, E.W. Kreutz and W. Gillner) 845
Reproduction of 3D Object Displays with Laser Systems
(S. Akkurt and M. Akkurt) 855
Laser Processing of Integrated Optic Waveguides for Photonic Applications
(A. Mukherjee, B.J. Eapen and S.K. Baral) 869
Optical and Acoustical Techniques for the Characterization of Material Ablation by
Q-switched Nd:YAG and Excimer l.aser Radiation
(c. Stauter, J. Fontaine, Th. Engel and A. Biemaux) 881
Advances in Laser Direct Writing
(T.M. Bloomstein, S.T. Palmacci, R.H. Mathews, N. Nassuphis and DJ. Ehrlich) 895
Laser Cleaning in Art Restoration: A Review
(K.G. Watkins, J.H. Larson, D.C. Emmony and W.M. Steen) 907
The Experience of Laser Heat Treatment Application in Industry of Ukraine
(V.S. Kovalenko) 925
Applications of the Nd:YAG Laser in Electronic Assembly Processes
(A. Flanagan and T.J. Glynn) 933
INTRODUCfION
The NATO Advanced Study Institute entitled "Laser Processing: Surface Treatment and Film
Deposition" was held July 3 through July 16, 1994 at Sesimbra, Portugal. This NATO ASI is a
follow up of the previous on the similar topic held September 2 through September 13, 1985 at
San Miniato, Italy. One significant difference in this program is the topic on ablation and ftlm
deposition. Experts in the fteld and scientists and engineers newly entering the fteld reviewed the
recent progress and innovations related to the science and technology of the laser surface treatment
and ftIm deposition. The papers presented in this ASI are contained in this proceedings.
This ASI proceedings is a comprehensive book dealing with the topic of laser surface treatment
and ftIm deposition. First, it provides an overview of the various processes. Second, fundamental
understandings of the processes are built with the discussion on the coupling mechanism of laser
materials interaction followed by theories on non-equilibrium synthesis, microstructure and phase
selection, interface response for rapid solidiftcation, modeling of transport phenomena (heat, mass
and momentum), and hydrodynamics of the process. Third, theoretical discussion was
complemented by discussion on various experimental measurement techniques for temperature,
plasma electron density and microstructure for theory validation and on-line process control.
Fourth, properties of many a laser processed materials are also discussed. Finally, speciftc
applications of laser surface modiftcation techniques such as alloying, cladding, laser chemical
vapor deposition, ablation, cleaning and heat treatment are described.
One distinct difference in this ASI compared to the last one is how much of the work described
related to the on-line diagnostics and model validation. This indicates an advancement of the fteld
and a transition toward implementation of the processes in the real world. New ftndings and
future research directions including suggestions for improvements of future NATO ASI's are
summarized at the beginning of this book.
We thank all the chairmen, lecturers and participants for organizing a comprehensive program,
illuminating presentations and stimulating discussions. Many scientiftc acquaintances have
become friends and future collaborators due to this intense interaction during the two-week period.
In spite of the inviting sandy beach and blue Atlantic waters of Sesimbra, scientiftc curiosity
seemed to have prevailed most of the time.
We would especially like to thank our major sponsor NATO ScientifIc Affairs Division who
funded the lion's share. We would also like to acknowledge the fmancial and moral support
from: Laser Institute of America, Luso-American Foundation, JNlCT (Junta Nacional de
Investigacao Cientiftca e Tecnologica), INVOT AN Commission, French Embassy (Lisbon) and
British Council (Lisbon), and Setubal Tourist Office. We are also very grateful to Dr. J. Choi,
Ms. Tammy Smith and Ms. Dianna Barnett of the University of illinois at Urbana-Champaign for
their help in the organization and preparation of this study Institute and the book.
J. Mazumder, University of Illinois at Urbana-Champaign
O. Conde, University of Lisbon
R. Vilar, Instituto Superior Tecnico
W.M. Steen, University of Liverpool
ix
GRADUATE STUDENT REPORT
Xiangli Chen
SUMMARY OF DISCUSSIONS AT THE NATO ASI
SESIMBRA, PORTUGAL, JULY 15, 1994
1. What have you heard here first?
* Developments of laser surface treatments in other countries (e.g. Ukraine) and laboratories.
* Different specific research topics:
binary alloy manufacturing with surface deposition
possibilities of designing properties
metallic particles in polymers
nanoscale microstructures
art cleaning by laser
possibilities of beam shaping
* Problems in understanding the energy coupling mechanisms in the classic methods of laser
surface treatment (hardening, remelting, alloying, and cladding).
* Dominance of high power CO lasers in classic fields of laser surface treatment.
2
* Laser safety research projects.
*
High quality thin films deposited by Excimer or Nd:YAG laser ablation processes.
*
Learning about basics and recent developments in other fields of laser surface treatment and
film deposition.
2. What are the most important conclusions you can make regarding the status of the field
from the tutorial lectures you have attended?
* A clear need for process control system to provide QA control which industry requires to turn
laboratory processes into commercially viable projects. Simple examples are the need to
measure surface temperature and beam qUality. Alternatively, it might be to electronically
record the quality of the process to provide long-term QA record for the manufacturer.
*
It was felt that laser surface treatment was still a technology driven science rather than by the
practical needs of industry.
* The use of laser surface processing was much more widely accepted in the electronic industry
than in mechanical industries.
xi