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Micromachines
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Laser-Based Micromachining, Structuring, and Polishing
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Laser-Based Micromachining, Structuring, and Polishing

A special issue of Micromachines (ISSN 2072-666X). This special issue belongs to the section "D：Materials and Processing".

Deadline for manuscript submissions: closed (30 May 2021) | Viewed by 15330

Special Issue Editor

Dr. Evgueni Bordatchev

E-Mail Website
Guest Editor
1. Department of Mechanical and Materials Engineering, Western University, London, ON N6A 6B9, Canada
2. Automotive and Surface Transportation, National Research Council of Canada, London, ON N6G 4X8, Canada
Interests: materials and processing: materials based micro/nano structures, devices, system, and its applications, bio-inspired surfaces; micro/nano fabrication and manufacturing: patterning, surface micromachining, bulk micromachining, laser fabrication, advanced manufacturing engineering
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Advanced laser-based microfabrication technologies, such as micromachining of complex parts and geometric features, structuring and texturing of functional surfaces, and polishing of tooling surfaces, are the key technologies for adding new and/or enhancing existing values of the functional parts and products. These technologies exhibit significant advantages over conventional processes in terms of the process reconfigurability, accuracy, precision, surface quality, versatility, processing time and cost, and minimal environmental impact. In addition, microfabrication technologies can be seamlessly integrated with novel material additive processes and systems for surface form and topography enhancement and functionalization.

The aim of this Special Issue is to cover advanced developments in laser-based microfabrication technologies towards design, modelling, microfabrication and performance evaluation of functional surfaces and their quality improvement for a wide range of applications related (but not limited) to the control of wettability, friction, optical appearance, light guiding, corrosion, hydro- and aero-dynamics, and biofouling. We invite full research papers, comprehensive reviews and communications covering related topics included in the keywords below. We would like to synergize the up-to-date innovative research from world-class investigators and leading experts in the field.

Dr. Evgueni Bordatchev
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Micromachines is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • Laser-based micromachining
  • Laser structuring
  • Laser polishing
  • Laser remelting
  • Laser alloying
  • Functional surfaces
  • High-quality tooling surfaces
  • Micro-/nano-structures for wettability control
  • Micro-/nano-structures for friction control
  • Micro-/nano-structures for hydro-/aero-dynamics control
  • Micro-/nano-structures for light guiding and optical holography
  • Micro-/nano-structures for biofouling control

Published Papers (5 papers)

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Research

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19 pages, 17169 KiB  
Article
Laser Surface Modification of TC21 (α/β) Titanium Alloy Using a Direct Energy Deposition (DED) Process
by Ahmed Magdi Elshazli, Ramadan N. Elshaer, Abdel Hamid Ahmed Hussein and Samar Reda Al-Sayed
Micromachines 2021, 12(7), 739; https://doi.org/10.3390/mi12070739 - 24 Jun 2021
Cited by 15 | Viewed by 2816
Abstract
The TC21 alloy (Ti-6Al-3Mo-1.9Nb-2.2Sn-2.2Zr-1.5Cr) is considered a new titanium alloy that replaced the commercial Ti-6Al-4V alloy in aerospace applications due to its higher operating temperatures. Recently, direct energy deposition was usually applied to enhance the hardness, tribological properties, and corrosion resistance for many [...] Read more.
The TC21 alloy (Ti-6Al-3Mo-1.9Nb-2.2Sn-2.2Zr-1.5Cr) is considered a new titanium alloy that replaced the commercial Ti-6Al-4V alloy in aerospace applications due to its higher operating temperatures. Recently, direct energy deposition was usually applied to enhance the hardness, tribological properties, and corrosion resistance for many alloys. Consequently, this study was performed by utilizing direct energy deposition (DED) on TC21 (α/β) titanium alloy to improve their mechanical properties by depositing a mixture powder of stellite-6 (Co-based alloy) and tungsten carbides particles (WC). Different WC percentages were applied to the surfaces of TC21 using a 4 kW continuous-wave fiber-coupled diode laser at a constant powder feeding rate. This study aimed to obtain a uniform distribution of hard surfaces containing undissolved WC particles that were dispersed in a Co-based alloy matrix to enhance the wear resistance of such alloys. Scanning electron microscopy, energy dispersive X-ray analysis (EDAX), and X-ray diffractometry (XRD) were used to characterize the deposited layers. New constituents and intermetallic compounds were found in the deposited layers. The microhardness was measured for all deposited layers and wear resistance was evaluated at room temperature using a dry sliding ball during a disk abrasion test. The results showed that the microstructure of the deposited layer consisted of a hypereutectic structure and undissolved tungsten carbide dispersed in the matrix of the Co-based alloy that depended on the WC weight fraction. The microhardness values increased with increasing WC weight fraction in the deposited powder by more than threefold as compared with the as-cast samples. A notable enhancement of wear resistance of the deposited layers was thus achieved. Full article
(This article belongs to the Special Issue Laser-Based Micromachining, Structuring, and Polishing)
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19 pages, 33792 KiB  
Article
Surface Structuring by Laser Remelting (WaveShape): Microstructuring of Ti6Al4V for a Small Laser Beam Diameter and High Scan Speeds
by André Temmler and Shan Qi
Micromachines 2021, 12(6), 660; https://doi.org/10.3390/mi12060660 - 03 Jun 2021
Cited by 4 | Viewed by 2339
Abstract
The appearance of a surface is a crucial characteristic of a part or component. Laser-based micromachining gets increasingly important in generating tailored surface topographies. A novel structuring technique for surface engineering is surface structuring by laser remelting (WaveShape), in which surface features are [...] Read more.
The appearance of a surface is a crucial characteristic of a part or component. Laser-based micromachining gets increasingly important in generating tailored surface topographies. A novel structuring technique for surface engineering is surface structuring by laser remelting (WaveShape), in which surface features are created without material loss. In this study, we investigated the evolution of surface topographies on Ti6Al4V for a laser beam diameter of 50 m and scan speeds larger than 100 mm/s. Surface features with aspect ratios (ratio of height to width) of almost 1:1 were achieved using the WaveShape process. Furthermore, wavelengths smaller than 500 m could be effectively structured using scan speeds of up to 500 mm/s. The experimental results showed further that the efficiency of the WaveShape process in terms of achieved structure height per unit time significantly increases for high scan speeds. Full article
(This article belongs to the Special Issue Laser-Based Micromachining, Structuring, and Polishing)
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14 pages, 12904 KiB  
Article
Shape Deviation of Surface Structures Produced by WaveShape (Structuring by Laser Remelting) on Ti6Al4V and a Method for Deviation Reduction
by Oleg Oreshkin, Daniil Panov, Laura Kreinest, André Temmler and Alexander Platonov
Micromachines 2021, 12(4), 367; https://doi.org/10.3390/mi12040367 - 29 Mar 2021
Cited by 3 | Viewed by 2528
Abstract
Laser structuring by remelting (WaveShape) is a manufacturing process for metal surfaces in which structures are generated without material removal. The structuring principle is based on the controlled motion of the three-phase line in the area of the solidification front. The contour of [...] Read more.
Laser structuring by remelting (WaveShape) is a manufacturing process for metal surfaces in which structures are generated without material removal. The structuring principle is based on the controlled motion of the three-phase line in the area of the solidification front. The contour of the solidification front is imprinted into the remelting track during the continuous solidification process. Typically, harmonic surface structures in the form of sinusoidal oscillations are generated by means of WaveShape with virtually no material loss. However, a significant shape deviation is often observed over a wide range of process parameters. In this study, it was found that much of the shape deviation is concentrated at a spatial wavelength equal to half the spatial wavelength used for structuring. Therefore, an approach to reduce the shape deviations was specifically investigated by superimposing a compensation signal on the harmonic structuring signal. In this approach, a compensation signal with half the spatial wavelength was varied in phase and amplitude and superimposed on the structuring signal. Amplitude and phase shift of the compensation signal were further investigated for selected laser beam diameters and spatial wavelengths. This demonstrated that a shape deviation of harmonic surface structures on titanium alloy Ti6Al4V could be reduced by up to 91% by means of an adapted compensation signal. Full article
(This article belongs to the Special Issue Laser-Based Micromachining, Structuring, and Polishing)
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Review

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46 pages, 13192 KiB  
Review
Laser Processing of Hard and Ultra-Hard Materials for Micro-Machining and Surface Engineering Applications
by Kafayat Eniola Hazzan, Manuela Pacella and Tian Long See
Micromachines 2021, 12(8), 895; https://doi.org/10.3390/mi12080895 - 28 Jul 2021
Cited by 23 | Viewed by 5570
Abstract
Polycrystalline diamonds, polycrystalline cubic boron nitrides and tungsten carbides are considered difficult to process due to their superior mechanical (hardness, toughness) and wear properties. This paper aims to review the recent progress in the use of lasers to texture hard and ultra-hard materials [...] Read more.
Polycrystalline diamonds, polycrystalline cubic boron nitrides and tungsten carbides are considered difficult to process due to their superior mechanical (hardness, toughness) and wear properties. This paper aims to review the recent progress in the use of lasers to texture hard and ultra-hard materials to a high and reproducible quality. The effect of wavelength, beam type, pulse duration, fluence, and scanning speed is extensively reviewed, and the resulting laser mechanisms, induced damage, surface integrity, and existing challenges discussed. The cutting performance of different textures in real applications is examined, and the key influence of texture size, texture geometry, area ratio, area density, orientation, and solid lubricants is highlighted. Pulsed laser ablation (PLA) is an established method for surface texturing. Defects include melt debris, unwanted allotropic phase transitions, recast layer, porosity, and cracking, leading to non-uniform mechanical properties and surface roughness in fabricated textures. An evaluation of the main laser parameters indicates that shorter pulse durations (ns—fs), fluences greater than the ablation threshold, and optimised multi-pass scanning speeds can deliver sufficient energy to create textures to the required depth and profile with minimal defects. Surface texturing improves the tribological performance of cutting tools in dry conditions, reducing coefficient of friction (COF), cutting forces, wear, machining temperature, and adhesion. It is evident that cutting conditions (feed speed, workpiece material) have a primary role in the performance of textured tools. The identified gaps in laser surface texturing and texture performance are detailed to provide future trends and research directions in the field. Full article
(This article belongs to the Special Issue Laser-Based Micromachining, Structuring, and Polishing)
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Other

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1 pages, 965 KiB  
Erratum
Erratum: Elshazli et al. Laser Surface Modification of TC21 (α/β) Titanium Alloy Using a Direct Energy Deposition (DED) Process. Micromachines 2021, 12, 739
by Ahmed Magdi Elshazli, Ramadan N. Elshaer, Abdel Hamid Ahmed Hussein and Samar Reda Al-Sayed
Micromachines 2021, 12(9), 1078; https://doi.org/10.3390/mi12091078 - 07 Sep 2021
Cited by 2 | Viewed by 1102
Abstract
In the original article [...] Full article
(This article belongs to the Special Issue Laser-Based Micromachining, Structuring, and Polishing)
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