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Eingeladener Vortrag
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Experimental investigation of the laser-plume interaction during high power fiber laser welding
(2011)
The effect of the well-known plasma absorption and refraction in CO2-laser metal welding plumes is in case of high power solid state laser welding negligibly small. By contrast, the diffraction effects of shorter wavelength laser radiation are considerable. According
to the results of preliminary studies, the fine condensed metal particles in the welding plume can lead to essential worsening of the laser beam quality.
This work is devoted to the investigation of the lasermatter interaction during up to 20 kW ytterbium fiber laser welding of thick mild steel plates. The plume attenuation of a probe 1.3 µm wavelength diode laser beam as well as of continuous radiation in 250-600 nm
wavelength range was measured during welding with and without Ar shielding gas supply. The measured results allow it to calculate average size and concentration of fine condensed metal particles in
different plume areas using the multi-wavelength method and the Mie scattering theory. The plume temperature, which determines the condensation conditions, was measured by means of Fe I atom
spectral line emission registration.
The obtained results can be also of interest for remote metal treatment with high-power fiber or disc lasers.
The Radon transform is tested as a method for reconstruction of the emissivity distribution of asymmetric laser induced plasmas. Two types of experiments were carried out. First, the plasma asymmetry is introduced via focusing the laser by a cylindrical lens to create plasma plumes elongated along the symmetry axis of the lens. Second, an asymmetric power distribution across the laser beam is created by reflecting the latter from a damaged mirror. Various effects on the quality of the plasma emissivity reconstructed by the Radon tomography method are investigated. The understanding of these effects appears to be essential to design a proper experimental setup to study LIBS plasmas by the Radon tomography method. It is demonstrated that the Radon tomography can successfully be used for experimental studies of asymmetric LIBS plasmas.
The Radon transform tomography is used for reconstruction of the emissivity distribution in single- (SP) and double-pulse (DP) laser induced plasmas in orthogonal geometry. The orthogonal DP plasma is intrinsically asymmetric and thus suitable for the Radon reconstruction. The DP plasma consists of two plasmas separated by a short time interval of ~ 1 µs. The first plasma is created in air near the surface of a Si wafer and is followed (pre-ablation mode) or preceded (post-ablation mode) by the second plasma induced on this surface. A spectrometer moves in a semi-circular path around the plasma keeping the plasma in the rotation center. The optical detection is arranged so that a thin plasma layer parallel to the target surface is monitored. The axial symmetry of the SP plasma is investigated by comparing data from the Abel inversion taken at different angles and Radon reconstruction. The multi-angle measurements are used to estimate errors of the Abel reconstruction due to asymmetries of the plasma. Time-resolved Radon reconstruction in white light is performed for the DP plasma in both pre- and post-ablation modes. In the former case, the effect of ablated aerosol on the formation of the air plasma is monitored. In the latter case, a formation of an asymmetric compression shock created by the target plasma inside the air plasma is visualized. This observation is supported by computer simulations. An interaction of the two plasmas is studied by spectrally resolved Radon reconstruction revealing a complex distribution of target and ambient species inside the plasma at all studied delay times. Overall, it is demonstrated that Radon-based tomography is an informative tool to study transient asymmetric laser induced plasmas.
Gated detection with intensified detectors, e.g., ICCDs, is today the accepted approach for detection of plasma emission in laser-induced breakdown spectroscopy (LIBS). However, these systems are more cost-intensive and less robust than nonintensified CCDs. The objective of this paper is to compare, both theoretically and experimentally, the performance of an intensified (ICCD) and nonintensified (CCD) detectors for detection of plasma emission in LIBS. The CCD is used in combination with a mechanical chopper, which blocks the early continuum radiation from the plasma. The detectors are attached sequentially to an echelle spectrometer under the same experimental conditions. The laser plasma is induced on a series of steel samples under atmospheric conditions. Our results indicate that there is no substantial difference in the performance of the CCD and ICCD. Signal-to-noise ratios and limits of detection achieved with the CCD for Si, Ni, Cr, Mo, Cu, and V in steel are comparable or even better than those obtained with the ICCD. This result is further confirmed by simulation of the plasma emission signal and the corresponding response of the detectors in the limit of quantum (photon) noise.
Raman and laser-induced breakdown spectroscopy is integrated into a single system for molecular and elemental microanalyses. Both analyses are performed on the same ~ 0.002 mm² sample spot allowing the assessment of sample heterogeneity on a micrometric scale through mapping and scanning. The core of the spectrometer system is a novel high resolution dual arm Echelle spectrograph utilized for both techniques. In contrast to scanning Raman spectroscopy systems, the Echelle-Raman spectrograph provides a high resolution spectrum in a broad spectral range of 200-6000 cm- 1 without moving the dispersive element. The system displays comparable or better sensitivity and spectral resolution in comparison to a state-of-the-art scanning Raman microscope and allows short analysis times for both Raman and laser induced breakdown spectroscopy. The laser-induced breakdown spectroscopy performance of the system is characterized by ppm detection limits, high spectral resolving power (15,000), and broad spectral range (290-945 nm). The capability of the system is demonstrated with the mapping of heterogeneous mineral samples and layer by layer analysis of pigments revealing the advantages of combining the techniques in a single unified set-up.
The purpose of this work is to improve the performance of a linear correlation method used for material identification in laser induced breakdown spectroscopy. The improved correlation procedure is proposed based on the selection and use of only essential spectral information and ignoring empty spectral fragments. The method is tested on glass samples of forensic interest. The 100% identification capability of the new method is demonstrated in contrast to the traditional approach where the identification rate falls below 100% for many samples.
This work is devoted to the investigation of the lasermatter interaction during up to 20 kW ytterbium fiber laser welding of thick mild steel plates. The plume attenuation of a probe 1.3 µm wavelength diode laser beam as well as of continuous radiation in the 250–600 nm wavelength range was measured during welding with and without Ar shielding gas supply. The measured results allow the calculation of the average size and concentration of fine condensed metal particles in different plume areas using the multi-wavelength method and the Mie scattering theory. The plume temperature, which determines the condensation conditions, was measured by means of Fe I atom spectral line emission registration. The spatial distribution of the extinction coefficient in the welding plume was measured and the plume attenuation of the high-power fiber laser beam during the welding process was estimated.
The authenticity of objects and artifacts is often
the focus of forensic analytic chemistry. In document fraud
cases, the most important objective is to determine the
origin of a particular ink. Here, we introduce a new
approach which utilizes the combination of two analytical
methods, namely Raman spectroscopy and laser-induced
breakdown spectroscopy (LIBS). The methods provide
complementary information on both molecular and elemental
composition of samples. The potential of this hyphenation
of spectroscopic methods is demonstrated for ten blue
and black ink samples on white paper. LIBS and Raman
spectra from different inks were fused into a single data
matrix, and the number of different groups of inks was
determined through multivariate analysis, i.e., principal
component analysis, soft independent modelling of class
analogy, partial least-squares discriminant analysis, and
support vector machine. In all cases, the results obtained
with the combined LIBS and Raman spectra were found to
be superior to those obtained with the individual Raman or
LIBS data sets.
An emission tomography of laser-induced plasmas employed in the laser induced breakdown spectroscopy (LIBS) requires signal integration times in a microsecond range during which the LIBS plasma cannot be considered stationary. Consequently, the use of the data for reconstructing the plasma properties under the assumption that the latter does not change significantly during the integration time leads to inaccurate results. To reduce the integration time, it is proposed to measure a plasma absorption in parallel rays using a scanning rectangular aperture whose dimension Δ along the scanning direction is about a characteristic size of plasma plumes (Δ ~ 1 cm) and the other dimension Δp is of the order of a uniformity length of plasma parameters (Δp ~ 10 µm). The aperture is moved step by step along the scanning direction and the total energy of photons coming through the aperture is measured during time T at each position of the aperture. Owing to the large size of the aperture, the integration time T is reduced by a factor ~ Δp/Δ. A numerical data processing is proposed to restore the spatial resolution of the plasma absorption along the scanning direction. It is determined by the scanning step Δs ≤ Δp. Another advantage of the proposed procedure is that inexpensive linear CCD or non-discrete (PMT, photodiode) detectors can be used instead of costly 2-dimensional detectors.
Abel inversion applied to a transient laser induced plasma: implications from plasma modeling
(2011)
We test the effects of non-uniformity, non-transparency, and non-stationarity of a laser-induced plasma on the results obtained by the Abel inversion method. The method is commonly used for obtaining spatially resolved emissivity of axially symmetric non-homogeneous radiating objects. Besides the axial symmetry, the plasma is assumed to be optically thin. As the method addresses a certain plasma state, the plasma is required to be stationary during measurements. It is difficult to satisfy the aforementioned conditions for transient laser induced plasmas. As such the plasmas are not stationary; they have steep gradients of thermodynamic parameters that rapidly vary during the plasma evolution. Therefore, any conclusion based on time-integrated measurements and the corresponding data processing should account for these effects. In this work, we use the collision-dominated plasma model to generate time- and spatially resolved synthetic spectra. The spectra are processed by executing the Abel inversion using two numerical algorithms. Thus obtained spatially resolved plasma parameters (emissivity, temperature, and number density) are compared with the exact parameters used to set up the model. In doing so, the accuracy of the Abel inversion method is assessed. Special attention is paid to the dynamic aspect of the expanding plasma and possible errors which result from time-integrated measurements.
The emission from doubly ionized species in laser-induced plasmas has not been properly investigated before since most analytical measurements were made at relatively long delays. This work proves that doubly ionized species, such as boron (B) III and iron (Fe) III, can exist during the first 150200 ns of the plasma lifetime in plasmas produced in air by typical lasers with irradiances of 109 1011 W/cm². The emission from these ions was detected using both the double- and single-pulse excitations.
The sum of the second ionization potential and the energy of corresponding excited states is approximately 30 eV. The presence of doubly charged ions in the early plasma was additionally confirmed by computer simulations using a collision-dominated plasma model. The Emission from doubly ionized species may be used for analytical purpose. For example, in the spectrum from a B–Fe ore, the B III analytical line at 206.6 nm is free from Fe spectral interference thus enabling the online laser-induced breakdown spectroscopy sorting of ores into three products with high, medium, and low B2O3 contents.
Comparison of single and double-pulse excitation during the earliest stage of laser induced plasma
(2011)
This paper deals with comparison of single-pulse (SP) and double-pulse (DP) excited plasmas during their earliest phase of life, from 0 to 500 ns. The samples are Si and Al and the irradiance per pulse is approximately 20 GWcm-2 under ambient conditions. It was found that at the beginning of a plasma lifespan, Si III and Al III ions were excited even under the SP excitation conditions and became much more abundant under DP excitation. The lifetime of doubly-ionized species was found to be very short, and after a delay of 200–300 ns they were not detected. The DP plasma differs from the SP plasma by the intensity of continuum radiation and by the width of emission lines, which are substantially narrower in the DP plasma. The intensity of light emitted from singly and, especially, doubly-ionized species is higher compared with neutral atoms; whereas the decay time of both neutral and ionized species is longer. An excitation mechanism for the DP plasma is proposed enabling qualitative and a quantitative explanation of the experimental data.
It is proposed to use apertures with large acceptance angles to reduce the integration time when studying the emissivity of laser induced plasmas by means of the Abel inversion method. The spatial resolution lost due to contributions of angled lines of sight to the intensity data collected along the plasma plume diameter is restored by a special numerical data processing. The procedure is meant for the laser induced plasma diagnostics and tomography when the integration time needed to achieve a reasonable signal to noise ratio exceeds a characteristic time scale of the plasma state variations which is short especially at early stages of the plasma evolution. It can also be used to improve the spatial resolution in a conventional experimental setup for plasma diagnostics.
We studied the confocal double-pulse laser-induced plasma in the very beginning of its life. It was found that the second laser pulse fired 0.7 to 5 µs after the first pulse produces plasma which, during the first 0 to 20 ns, resembles solar configuration. There is a very hot and compact plasma core that radiates a broad continuum spectrum and a much larger and cooler outer shell. The light from the hot core passes through the cold outer shell and is partly absorbed by atoms and ions that are in ground (or close to ground) states. This produces absorption lines that are similar to Fraunhofer lines observed in the sun spectrum. The possibility to use these absorption lines for new direct and calibration free laser-induced breakdown spectroscopy analytical applications, both in laboratory and industrial conditions, is proved.
Probe diagnostics is used to determine the electron temperature and electron number density in a low pressure inductively coupled plasma (ICP) ignited in the mixture of SiF4, Ar and H2. Emission spectra of mixtures with different stoichiometry of components are investigated and the electron density distribution function (EDDF) is estimated. The optimal conditions for high conversion of SiF4 into Si are found by studying the dependence of the yield of silicon upon the ratio of reagents. The maximum achieved yield of silicon is 85% under the optimal conditions. Based on the analysis of IR and MS spectra of exhaust gases, 5% of initial SiF4 converts into volatile fluorosilanes. A rate of production of Si is 0.9 g/h at the energy consumption 0.56 kWh /g.
Laser-induced plasmas are widely used in many areas of science and technology; examples include spectrochemical analysis, thin film deposition, and material processing. Several topics will be addressed. First, general phenomenology of laser-induced plasmas will be discussed. Then, a chemical model will be presented based on a coupled solution of Navier-Stokes, state, radiative transfer, material transport, and chemical equations. Results of computer simulations for several chemical systems will be shown and compared to experimental observations obtained by optical imaging, spectroscopy, and tomography. The latter diagnostic tools will also be briefly discussed. Finally, a prospective application of laser-induced plasma and plasma modeling will be illustrated on the example of chemical vapor deposition of molybdenum borides and micro processing and coating of titanium dental implants.
Laser metal deposition is a rapidly evolving method for additive manufacturing that combines high performance and simplified production routine. Quality of production depends on an instrumental design and operational parameters, which require constant control during the process. In this work, feasibility of using optical spectroscopy as a control method is studied via modeling and experimentally. A simplified thermal model is developed based on the time-dependent diffusion-conduction heat equation and geometrical light collection into detection optics. Intense light emitted by a laser-heated spot moving across a sample surface is collected and processed to yield the temperature and other temperature-related parameters. In the presence of surface defects, the temperature field is distorted in a specific manner that depends on shape and size of the defect. Optical signals produced by such the distorted temperature fields are simulated and verified experimentally using a 3D metal printer and a sample with artificially carved defects. Three quantities are tested as possible metrics for monitoring the process: temperature, integral intensity, and correlation coefficient. The shapes of the simulated signals qualitatively agree with the experimental signals; this allows for a cautious inference that optical spectroscopy can detect surface defects and, possibly, predict their characters, e.g., inner or protruding.
Equilibrium model of titanium laser induced plasma in air with reverse deposition of titanium oxides
(2022)
A chemical-hydrodynamic model of laser induced plasma is developed to study a process of deposition of titanium oxides from titanium laser induced plasma to the titanium target surface. The model is relevant to texturing and coating of titanium bone implants that is done by scanning the ablation laser across implant surfaces. Such the procedure improves the biocompatibility and durability of the implants. The model considers plasma chemical reactions, formation of condensed species inside the plasma plume, and deposition and accumulation of these species on the ablation surface. A chemical part of the model is based on minimization of Gibbs free energy of the chemical system; it is used to calculate the chemical composition of the plasma. A hydrodynamic part uses the 2D fluid-dynamic equations that model a 3D axisymmetric plasma plume and assumes the mass and energy exchange between the plasma and the surface. The initial parameters for the model are inferred from experiment.
The model shows that condensed titanium oxides, mostly TiO2, form in a peripheral plasma zone and gradually adhere to the surface during the plasma plume evolution. The model predicts the major component and thickness of the deposit and can be applied for the optimization of experiments aimed at surface modification.
Back Deposition of Titanium Oxides under Laser Ablation of Titanium: Simulation and Experiment
(2022)
Titanium is widely used in medicine for implants and prostheses, thanks to its high biocompatibility, good mechanical properties, and high corrosion resistance. Pure titanium, however, has low wear resistance and may release metallic titanium into surrounding tissues. Structuring and coating its surface with oxide layers are necessary for high wear resistance and improved biocompatibility. In this work, a combination of theoretical and experimental methods was used to study processes responsible for deposition of titanium oxides during ablation of titanium in air.
The deposition process was modeled via the Navier-Stokes equations that accounted for the material removal and accumulation of the deposit on the ablation surface. The chemical part was based on the equilibrium model embedded into the hydrodynamic code. Simulations showed that the most active zone of production of condensed titanium oxides were at plasma periphery whereas a zone of strong condensation of titanium metal was above the molten pool.
In experiment, a pulsed Yb fiber laser was scanned across a titanium surface. The temperature and composition of the plasma were inferred from plasma emission spectra. The post-ablation surface was analyzed by SEM, TEM, STEM, AFM, and XRD.
The developed model well reproduced the main features of experimental data. It was concluded that the deposition of condensed metal oxides from the plasma is a principal mechanism of formation of nanoporous oxide layer on the metal surface. The method of surface structuring and modification by nanosecond laser ablation can be developed into a useful technology that may find applications in medicine, photonics, and other areas.
The deposition of titanium oxides during titanium laser ablation in air has been experimentally and numerically investigated. A titanium sample was irradiated by nanosecond pulses from an Yb-fber laser with a beam scanned across the sample surface for its texturing. As a result, the hierarchical structure was observed consisting of a microrelief formed by the laser ablation and a nanoporous coating formed by the reverse deposition from the laser induced plasma plume. The chemical and phase composition of the nanoporous coating, as well as the morphology and structure of the surface, were studied using scanning electron microscopy, atomic force microscopy, and X-ray microanalysis. It was found that the deposit consists mostly of porous TiO2 with 26% porosity and inclusions of TiO, Ti2O3, and Ti2O3N. Optical emission spectroscopy was used to control the plasma composition and estimate the effective temperature of plasma plume. The chemical-hydrodynamic model of laser induced plasma was developed to get a deeper insight into the deposition process. The model predicts that condensed titanium oxides, formed in peripheral plasma
zones, gradually accumulate on the surface during the plasma plume evolution. A satisfactory agreement between the experimental and calculated chemical composition of the plasma plume as well as between the experimental and calculated composition and thickness of the deposited film was demonstrated. This allows a cautious conclusion that the formation of condensed oxides in the plasma and their consequent deposition onto the ablation surface are among the key mechanisms of formation of porous surface films.
Formation and detection of molecules in laser induced plasmas (LIP) is a hot topic. In analytical plasmas like LIBS, the detection of molecules is important for identification of geological and other materials, analysis of isotopes and difficult elements (Cl, F, etc.) via molecular emission. In chemical plasmas, like PECVD (plasma enhanced chemical vapor deposition) or PLD (pulsed laser deposition), molecules formed in the plasma determine a composition and a thickness of deposits. Similarly, molecules play an important role in microstructuring and oxidizing metal surfaces by laser ablation. It is unfortunate that different communities, which utilize plasma methods and seek for solutions of similar problems, do not strongly overlap, and do not fully use knowledge accumulated by each other.
In this presentation, mechanisms of formation of molecules will be analyzed on the example of LIPs used for chemical vapor deposition and metal microstructuring. Theoretical analysis includes equilibrium chemistry calculations combined with plasma hydrodynamics. First, LIP excited in a gas mixture of BCl3 or BF3 with H2 or CH4 will be analyzed; this chemical system is used for obtaining deposits of refractory solid boron and boron carbide. Second, a breakdown in the SiF4 + SiCl4 gas mixtures will be described; this method allows synthesis of fluorochlorosilanes SiFxCl4-x (x = 1, 2, 3), the good etching agents (Figure). Third, solid ablation of Mo in BF3+H2 and Ti in air will be considered aimed at obtaining deposits of high hardness MoxBy and films of TixOy on textured Ti surfaces, correspondingly.
In experiment, reaction gases before and after laser illumination, and solid deposits are analyzed by optical emission spectroscopy (OES), IR and mass spectrometry (MS), SEM, X-ray, and AFM. It will be shown that the hydrodynamic-chemical model adequately predicts the composition of LIPs, zones of molecular formation, dependence on reactant stoichiometry, plasma temperature and pressure.
Additive manufacturing by laser metal deposition (LMD) requires continuous online monitoring to ensure quality of printed parts. Optical emission spectroscopy (OES) is proposed for the online detection of printing defects by monitoring minute variations in the temperature of a printed spot during laser scan. A two-lens optical system is attached to a moving laser head and focused on a molten pool created on a substrate during LMD. The light emitted by the pool is collected by an ultraviolet–visible (UV–vis) spectrometer and processed.
Two metrics are used to monitor variations in the surface temperature: the spectrally integrated emission intensity and correlation coefficient. The variations in the temperature are introduced by artificial defects, shallow grooves, and holes of various widths and diameters carved on a substrate surface. The metrics show sufficient sensitivity for revealing the surface defects, except for the smallest
holes with an under-millimeter diameter. Additionally, numeric simulations are carried out for the detection of emission in the UV–vis and near-infrared (NIR) spectral ranges at various surface temperatures. It is concluded that both the metrics perform better in the NIR range. In general, this work demonstrates that spectrally resolved OES suits well for monitoring surface defects during 3D metal
printing.
A brief introduction will be given on modeling chemical reactions in laser induced plasmas using stoichiometric and non-stoichiometric approaches. Several applications will be considered, which can benefit from such modeling. Those include plasma enhanced chemical vapor deposition (PECVD), surface modification and surface coating, and molecular analysis by LIBS. Each application will be illustrated by simulations of relevant chemical systems. For PECVD, chemical systems are BCl3/H2/Ar, BF3/H2/Ar, BCl3/BF3, Mo/BF3/H2; for surface modification/coating it is Ti/air; for molecular LIBS they are CaCO3/Ar, Ca(OH)2/Ar, and CaCl2/Ar. Advantages and shortcomings of equilibrium chemical hydrodynamic models of laser induced plasmas will be discussed.
This course will provide an introduction to plasma diagnostic techniques. The major focus of the course will be on the discussions of the practical procedures as well as the underlying physical principles for the measurements of plasma fundamental characteristics (e.g., temperatures and electron number density). Particular emphasis will be placed on laser induced plasma–atomic emission spectrometry, but other analytical plasmas will also be used as examples when appropriate. Selected examples on how one can manipulate the operating conditions of the plasma source, based on the results of plasma diagnostic measurements, to improve its performance used for spectrochemical analysis will also be covered. Topics to be covered include thermal equilibrium, line profiles, temperatures, electron densities, excitation processes, temporal and spatial resolution.
Surface modification of titanium by laser ablation is investigated theoretically and experimentally. The modification consists in texturing the surface and redeposition of chemically transformed material from the ablation plasma. The redeposition is driven by the hydrodynamic flow in the plasma. Such surface modification improves the biocompatibility of titanium implants.
Laser induced dielectric breakdown (LIDB) on a surface of solid Mo in H2/BF3 atmosphere at 30-760 Torr and in a gaseous mixture MoF6/H2/BF3 + at 760 Torr pressure is tested for synthesis and deposition of superhard molybdenum borides that are needed in many areas of industry and technology. The emission spectra of the plasma and the dynamics of the gas discharge near the substrate are investigated. A comparative analysis of the gas mixture before and after exposure to LIDB plasma is carried out using IR spectroscopy. The conditions for the formation of molybdenum borides are determined. A thermodynamic analysis of the MoF6/H2/BF3 and Mo/H2/BF3 systems is carried out to determine the temperature range for the formation of molybdenum borides and establish the main chemical reactions responsible for their formation. Deposits containing MoB and MoB2 phases are obtained. For the mixture MoF6/H2/BF3, the deposit exhibits an amorphous layered structure, which contains 19.15 wt% F, 30.45% O, and 0.8% Si. For the Mo/H2/BF3 system at the pressures 30 and 160 Torr, nanopowder of molybdenum boride is produced with a characteristic grain size of 100 nm. At pressures above 160 Torr, Mo nanopowder with a grain size <30 nm is obtained.
The presentation will give a brief overview of the processes occurring in laser-induced plasma and methods of modeling these processes. In particular, a chemical-hydrodynamic model will be considered, which is related to the modification of the surface of metallic titanium by laser pulses. The details and simplifications of this model, its shortcomings and the possibilities of their elimination will be discussed. This model is related to the structuring of the surface of dental implants with a laser and the deposition of an oxide film on it.
Vor allem in den letzten Jahren ist das Interesse der Industrie an der additiven Fertigung deutlich gestiegen. Die Vorteile dieser Verfahren sind zahlreich und ermöglichen eine ressourcenschonende, kundenorientierte Fertigung von Bauteilen, welche zur stetigen Entwicklung neue Anwendungsbereiche und Werkstoffe führen. Aufgrund der steigenden Anwendungsfälle, nimmt auch der Wunsch nach Betriebssicherheit unabhängig von anschließenden kostenintensiven zerstörenden und zerstörungsfreien Prüfverfahren zu. Zu diesem Zweck werden im Rahmen des von der BAM durchgeführten Themenfeldprojektes „Prozessmonitoring in Additive Manufacturing“ verschiedenste Verfahren auf ihre Tauglichkeit für den in-situ Einsatz bei der Prozessüberwachung in der additiven Fertigung untersucht. Hier werden drei dieser in-situ Verfahren, die Thermografie, die optische Emissionsspektroskopie und die Schallmissionsanalyse für den Einsatz beim Laser-Pulver-Auftragschweißen betrachtet.
Superhard materials with a Vickers hardness in the range of 30-40 GPa are of great interest, both from a fundamental and a practical viewpoints, since they have outstanding mechanical, thermal and chemical properties. Molybdenum borides belong to this group of materials. A review of publications on synthesis of molybdenum boride indicates a) great interest in this superhard material and b) the need for new effective methods of its synthesis, especially in a nanocrystalline form.
Very promising are the plasma-chemical methods based on laser induced breakdown. The breakdown can be created either in reactive gases containing volatile compounds of boron and molybdenum or on solid samples. For gas breakdown, molybdenum hexafluoride MoF6 and boron trifluoride BF3 were used in the mixture with hydrogen and argon; for solid breakdown, the pure molybdenum sample was ablated into the mixture of H2 and BF3.
The plasma-chemical synthesis of MoxBy structures was carried out in the reactor shown in Figure. Laser breakdown was created by a pulsed Nd: YAG laser operating at 1064 nm with a 15 ns pulse duration, 5 Hz repetition rate, and 800 mJ pulse energy. The laser was focused by a 5 cm focal length lens to produce 26 J/cm3 energy density in the focal point. The ratios H2:BF3: MoF6 = 5:2:1 and H2:BF3 = 3:1 were used in a pressure range 30 - 760 Torr.
After ablation in the mixture H2 + BF3 + MoF6, the deposit contained an amorphous phase with a small impurity of crystalline molybdenum and no boride phase. After ablation of metallic Mo into H2 + BF3, the main phase was MoB2 in the form of nano dispersed powder with an average grain size of 100 nm. The degree of conversion of boron trifluoride and the yield of molybdenum boride were studied as a function of pressure. It was established that 30 Torr is optimal for the formation of MoB2. This work was supported by the Russian Science Foundation grant No. 20-13-00035.
A brief introduction will be given on modeling chemical reactions in laser induced plasmas using stoichiometric and non-stoichiometric approaches. Several applications will be considered, which can benefit from such modeling. Those include plasma enhanced chemical vapor deposition (PECVD), surface modification and surface coating, and molecular analysis by LIBS. Each application will be illustrated by simulations of relevant chemical systems. For PECVD, chemical systems are BCl3/H2/Ar, BF3/H2/Ar, BCl3/BF3, Mo/BF3/H2; for surface modification/coating it is Ti/air; for molecular LIBS they are CaCO3/Ar, Ca(OH)2/Ar, and CaCl2/Ar. Advantages and shortcomings of equilibrium chemical hydrodynamic models of laser induced plasmas will be discussed.
Laser-induced breakdown spectroscopy (LIBS) and principal component analysis (PCA) are frequently used for analytical purposes in research and industry, but they seldom are part of the chemistry Curriculum or laboratory exercises. This case study paper describes the combined application of LIBS and PCA during a research internship for an undergraduate student. The instructional method applied was based on a one-on-one mentorship, in which case the learner was engaged in a Research work. The learning activities included theoretical introductions to the LIBS and PCA methods, numerical simulation, experiments, and data analysis.
The study covered three main topics: analysis of LIBS spectra, application of PCA for clustering, and use of PCA for experimental design. The realization of the study was instructive for all parties involved: from the mentorship point of view, it is concluded that the topics can be covered during an internship or developed into a one semester long research-based module of a chemistry program or a final year project. The student, on the other hand, developed profound technical skills in performing experiments and using PCA software for data analysis.
Important chemical process of reduction of SiF4 by hydrogen is realized in laser induced dielectric breakdown (LIDB) plasma in a gas mixture of SiF4 and H2. The process may be an alternative to a method of Plasma enhanced chemical vapor deposition (PECVD) which is commonly used for production of pure and isotopically pure silicon films. The composition of laser induced plasma in gases SiF4, SiF4 + H2, SiF4 + H2 + Ar at atmospheric pressure is studied and compared to the composition of inductively coupled plasma (ICP) in the same gases but at reduced pressure of 3 Torr. The gaseous products of chemical reactions are inferred from optical emission spectroscopy (OES) and IR spectroscopy. The reaction products of silicon fluoride SiF and fluorosilanes SiHxFy (x, y = 1, 2, 3) in LIDB plasma are observed and confirmed by equilibrium chemistry calculations and simulations of plasma expansion dynamics using a fluid dynamic-chemical plasma model. It is further suggested that chemisorption of fluorinated species like SiFx (x = 1, 2) followed by the surface reaction with H-atoms lead to a formation of silicon-to‑silicon bonds on a substrate surface. A conclusion is drawn that energetic laser
induced plasma can prove efficient for one-step PECVD by hydrogen reduction of SiF4.
Plasma-chemical approach is used for synthesis of various gaseous, liquid, and solid substances since 1960th. Nowadays, the method of plasma enhanced chemical vapor deposition (PECVD) is used for production of thin films, protective coatings, carbon-based nanostructures, high purity isotopic materials, biomaterials, and other products. Plasma for PECVD is typically created in various electrical discharges, e.g. DC and AC glow discharges or discharges operated at audio (10-20 kHz), radio (13.56 MHz), and microwave (2.45 GHz) frequencies. Plasma induced by a laser, a laser induced plasma (LIP), is rarely used to deposit materials from the gas phase as in PECVD. This work is aimed at reviving interest to this latter technology and showing its efficiency and potential.
We run several pilot experiments. First, LIP is excited in BCl3 or BF3 plus H2 or CH4 to evaluate the efficiency of deposition of solid boron and boron carbide, the materials, which are largely used for refractory coatings. Second, we investigate a possibility of synthesis of fluorochlorosilanes SiFxCl4-x (x = 1, 2, 3) by LIP induced in SiF4 + SiCl4 gas mixtures. Using fluorochlorosilanes with different combinations of F and Cl in the SiFxCly molecule may add flexibility in processes of silicon deposition and etching. Third, LIP is excited in reactive mixture MoF6+H2+BF3 or on a Mo target ablated into H2/BF3 atmosphere. The goal is obtaining superhard molybdenum borides MoB, Mo2B, or MoB2. The gases used and solid deposits are analyzed by optical emission spectroscopy (OES), IR and mass spectrometry (MS).
We also model the plasma and perform static equilibrium chemistry calculations to see if the desired reaction products are thermodynamically favorable. Dynamic calculations of the expanding plasma plume are performed using a hydrodynamic code combined with the open source chemical software.
Im Rahmen des Themenfeldprojektes „Process Monitoring of AM“ (ProMoAM) evaluiert die Bundesanstalt für Materialforschung und -Prüfung (BAM) gegenwärtig die Anwendbarkeit verschiedenster ZfP-Verfahren zur in-situ Prozessüberwachung in der additiven Fertigung (AM) von Metallen in Hinblick auf die Qualitätssicherung.
Einige der wichtigsten Messgrößen sind hierbei die Temperatur des Schmelzbades und die Abkühlrate, welche starken Einfluss auf das Gefüge und die Eigenspannung haben. Aufgrund der Zugänglichkeit zum Werkstück während des Bauprozesses bieten sich optische Verfahren zu Temperaturbestimmung an. Hierbei stellen jedoch u. a. die hohe Bandbreite der zu messenden Temperaturen, die Bestimmung der Emissivität und ihre Änderung bei Phasenübergängen der verwendeten Legierung große experimentelle Herausforderungen dar. Eine weitere Herausforderung stellt für die IR-Spektroskopie die Absorption durch das Schutzgas und weitere optische Elemente dar. Um diese auch in einem industriellen Umfeld kompensieren zu können, wurde eine Methode entwickelt, die das gemessene Spektrum bei der Verfestigung des Werkstoffes als Referenz nutzt. In diesem Beitrag wird die Anwendung dieser Methode für die IR-Spektrometrie als auch Thermografische Messungen beim Laser-Pulver-Auftragschweißen von 316L gezeigt, wobei beide Methoden weiterhin in Hinblick auf ihre individuellen Vor- und
Nachteile miteinander verglichen werden.
Processes of laser induced oxidation of metals are typically studied in the framework of heterogeneous chemical reactions occurring on the irradiated surface, which lead to the formation of dense oxide films deposited on it. Such technology has many applications like color-laser marking technology and laser recording on thin metal films for creation of diffractive optical elements . Under the conditions of strong laser ablation, another oxidation mechanism becomes possible: evaporated atoms react with oxygen in a surrounding atmosphere and the products of such reaction are redeposited back onto the substrate. The chemical and phase composition of such deposited layer, its density, morphology and structure depend on the conditions of laser ablation. By varying these conditions, the main properties of such coating can be controlled that is important for some potential application (for example in biomedicine).
In our report we present the study of the processes of redeposition of oxides structure under the conditions of multipulse nanosecond laser ablation of titanium (Grade 2) in air atmosphere at normal conditions. Our experiments show that titanium-implants with such deposited oxide layer have increased biocompatibility.
Modelling of chemical reaction in laser-induced plasma coupled with experimental methods of plasma optical emission spectroscopy allows us to determine the types of main chemical reactions in laser plasma as well as it influences on the plume dynamics and vapor condensation kinetics. As a result, we propose the general physical picture of reverse deposition of oxides structure under the condition of strong nanosecond laser ablation. The formation of the titanium oxide precipitate is explained not only by collisions in the plasma, but also by the chemical interaction of titanium and oxygen, which leads to the formation of а low pressure area near the substrate and additionally stimulates the reverse deposition of oxides. We expect, similar processes are valid not only for titanium but also for other metals and, possibly, semiconductors.
Laser metal deposition is a rapidly evolving method for additive manufacturing that combines high performance and simplified production routine. Quality of production depends on instrumental design and operational parameters that require constant control during the process. In this work, feasibility of using optical spectroscopy as a control method is studied via modeling and experimentally. A simplified thermal model is developed based on the time-dependent diffusion-conduction heat equation and geometrical light collection into detection optics. Intense light emitted by a laser-heated spot moving across a sample surface is collected and processed to yield the temperature and other temperature-related parameters. In a presence of surface defects the temperature field is distorted in a specific manner that depends on a shape and size of the defect. Optical signals produced by such the distorted temperature fields are simulated and verified experimentally using a 3D metal printer and a sample with artificially carved defects. Three quantities are tested as possible metrics for process monitoring: temperature, integral intensity, and correlation coefficient. The shapes of the simulated signals qualitatively agree with the experimental signals; this allows a cautious inference that optical spectroscopy is capable of detecting a defect and, possibly, predicting its character, e.g. inner or protruding.
Laser metal deposition is a rapidly evolving method for additive manufacturing that combines high performance and simplified production routine. Quality of production depends on instrumental design and operational parameters that require constant control during the process. In this work, feasibility of using optical spectroscopy as a control method is studied via modeling and experimentally. A simplified thermal model is developed based on the time-dependent diffusion-conduction heat equation and geometrical light collection into detection optics. Intense light emitted by a laser-heated spot moving across a sample surface is collected and processed to yield the temperature and other temperature-related parameters. In a presence of surface defects the temperature field is distorted in a specific manner that depends on a shape and size of the defect. Optical signals produced by such the distorted temperature fields are simulated and verified experimentally using a 3D metal printer and a sample with artificially carved defects. Three quantities are tested as possible metrics for process monitoring: temperature, integral intensity, and correlation coefficient. The shapes of the simulated signals qualitatively agree with the experimental signals; this allows a cautious inference that optical spectroscopy is capable of detecting a defect and, possibly, predicting its character, e.g. inner or protruding.
In this presentation, I will give a brief overview of my personal experience with laser induced plasma (LIP). I will start from my and colleagues’ early works, where we used LIP as an atomic reservoir for laser induced fluorescence (LIP). We applied LIP-LIF for a sensitive detection of trace elements in various materials and demonstrated that under certain conditions the technique can even be used for isotope analysis. Next, I will discuss the application of LIP spectroscopy, i.e., LIBS, to material identification that nowadays constitutes one of the best applications of this technique. In those early days, we used correlation analysis for spectra processing; it is now replaced by more powerful chemometric methods. Further, I will stop on our efforts in modeling LIP that we first intended for the improved quality of spectroscopic analysis and later extended to non-spectroscopic fields such as chemical vapor deposition and surface structuring. We developed a version of calibration-free LIBS, in which we iterated model-generated spectra until a close match was achieved between experimental and synthetic spectra to determine concentrations. Next, I will briefly overview our recent developments in plasma modeling that include plasma chemistry. This was important in view of widening application of LIBS as a molecular technique. I will also address several plasma diagnostics, e.g., Radon transform tomography that we developed to get more insight about LIP that was helpful for both analytic spectroscopy and modeling. Finally, I will mention several exotic applications of LIP such as LIP-based lasers and chemical reactors to illustrate a real multifaceted character of laser induced plasma and usefulness of its study for many science fields.