Direct Laser Interference Patterning (DLIP) is an established technology for producing textured and functional surfaces using beam-shaped laser radiation. It consists of producing high-intensity interference patterns by overlapping two or more laser beams at the material surface. In this work, new possibilities for producing textured surfaces on metals and polymers using high-throughput concepts for DLIP are presented. The first concept describes the development of a new DLIP optical head (called xDLIP) with an outstanding depth of focus of approximately 10 mm, which can be equipped with fs, ps or ns pulsed laser systems. This approach makes this device ideal to treat large areas as well as three-dimensional parts. In particular, a setup using an industrial robot system is shown. The second approach includes the combination of a new DLIP optical system with a polygon scanner, showing the possibility to treat metallic and polymer surfaces. This includes configurations for reaching 7.0 and 21.0 μm spatial periods at throughputs beyond 1 m2/min. Finally, DLIP is implemented into a roll-to-roll process using a high-power picosecond pulsed laser source, in which the main laser beam is shaped into two elongated beams which go through a scanner system. Using this setup, aluminum and copper foils with thicknesses of 20 μm and 9 μm, respectively, are processed.
Additive Manufacturing methods enable the fabrication of complex 3D components for a wide range of applications, ranging from prototyping up to part manufacturing in industrial several sectors including aerospace and medical industries. In particular, the surface quality of these parts have to be improve in order to reach standard qualities or to obtain specific surface functions. In this frame, this research work reports on laser-based surface finishing treatments of additive manufactured specimens consisting on a new innovative aluminum-alloy (Scancromal®). The experiments are performed with a picosecond pulsed-laser system operating at a fundamental wavelength of 1064 nm, aiming the fabrication of functionalized surfaces with improved properties through topographical features in the micrometer range. To characterize the surface topography, the specimens are analyzed using Confocal Microscopy (CM) and Scanning Electron Microscopy (SEM). Contact Angle measurements are used for the determination of wetting and icing-repellent characteristics of lasertreated AM substrates. Additionally, surface free energy (SFE) is determined and compared with the reference samples. The results show a significant influence of the laser treatment on the surface quality of the treated samples and its resulting wettability behavior. For instance, the water contact angle (WCA) could be increased from 62° to 134°, while the freezing time is also increased from 11 to 25 s after laser treatment, which can be an advantage for some applications and extend the feasibility of AM components beyond the current state of the art.
Additive Manufacturing (AM) processes enable the fabrication of complex three dimensional lightweight parts in a simple way, making these technologies attractive and viable for a wide range of applications in industrial sectors such as aerospace and medical industry. However, it is well known that surfaces of AM components have a relative high roughness level, which can limit their applicability in industrial fields. This study describes the surface modification of AM parts by Direct Laser Writing (DLW) and Direct Laser Interference Patterning (DLIP) to improve the surface quality of additive manufactured specimens made of Titanium 6Al 4V (Ti64) and an Al-Mg-Sc based alloy (Scalmalloy®). The experiments are carried out with an Ytterbium fiber laser and a Nd:YVO4 solid-state laser for DLW and DLIP process, respectively. The DLW laser process enabled the reduction of the initial surface roughness as well as facilitating the fabrication of defined periodical textures with feature sizes in the micrometer range, implemented by DLIP. These textures permitted to control the wettability of the surfaces. The laser treated and non-processed parts are characterized using White Light Interferometry (WLI), Confocal Microscopy (CM) and Scanning Electron Microscopy (SEM). Additionally, the wettability behavior was analyzed through long-term water contact angle measurements over a period of 50 days.
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