Laser-based Technologies for Sustainable Manufacturing

Half Title
Series Page
Title Page
Copyright Page
Contents
Aim and Scope
Preface
Acknowledgment
Editors
Contributors
Chapter 1: Introduction to Optics and Laser-Based Manufacturing Technologies
1.1 Introduction
1.2 Optics
1.2.1 Concepts of Optics Geometry
1.2.2 Optics Geometry
1.2.3 The Approximation of Ray
1.2.4 Reflection
1.2.5 Law of Reflection
1.2.6 Specular and Diffuse Reflection
1.2.7 Refraction
1.2.8 Law of Refraction
1.3 Mirror and Lenses
1.3.1 Mirror
1.3.1.1 Mirror with a Concave Surface
1.3.1.2 Mirror with a Convex Shape
1.3.1.3 Reflecting in a Parabola
1.3.2 Lens
1.3.2.1 Convex Lens
1.3.2.2 Types of Convex Lenses
1.3.2.2.1 "Plano Convex Lenses"
1.3.2.2.2 Convex and Concave Lenses
1.3.2.2.3 The Concave-Convex Lenses
1.3.2.3 Concave Lens
1.3.2.4 Types of Concave Lens
1.4 Laser
1.4.1 Lasers Types
1.4.1.1 Gas-Discharge Lasers
1.4.1.1.1 Helium Neon (HeNe) Lasers
1.4.1.1.2 Helium Cadmium (HeCd) laser
1.4.1.1.3 Noble-Gas Ion Lasers
1.4.1.1.4 Carbon dioxide (CO2) Lasers
1.4.1.1.5 Excimer Lasers
1.4.1.2 Semiconductor Diode Lasers
1.4.1.3 Diode-Pumped Solid State Lasers
1.4.1.3.1 Microchip Lasers
1.5 Lasers in Manufacturing
1.6 Laser Metal Deposition
1.7 Lasers in Additive Manufacturing
1.7.1 Use of Lasers in Additive Manufacturing
1.7.1.1 CO2 Laser
1.7.1.2 Solid-State Nd: YAG Laser
1.7.1.3 Yb-Doped Fiber Laser
1.7.1.4 Excimer Gas Laser
1.8 Laser Parameters in 3D Printing
1.8.1 Operating Wavelength
1.8.2 Average Power Pulse Energy Intensity
1.8.3 Pulse Duration
1.8.4 Beam Quality and Focused Spot Size
1.9 Laser for 3D Printing Technology
1.9.1 Stereolithography (SLA)
1.9.2 Selective Laser Sintering (SLS)
1.9.3 Selective Laser Melting (SLM)
1.9.4 Laser-Guided Net Engineering (LENS)
1.10 Laser-Based Macro-Scale Metal AM Challenges
1.10.1 Interface Defects
1.10.2 Powder Contamination
1.10.3 Pre-Processing Software
1.10.4 Experimental Design
1.11 Industrial Applications
1.11.1 Photolithography
1.11.2 Marking and Scribing
1.11.3 Noncontact Measurement
1.11.4 Scientific Applications
1.11.4.1 Time-Resolved Spectroscopy
1.11.4.2 Confocal Scanning Microscopy
1.11.4.3 TIR and Fluorescence Correlation Spectroscopy
1.11.4.4 Microarray Scanning
1.11.5 Clinical and Medical Applications
1.11.5.1 Flow Cytometry
1.11.5.2 Surgical Applications
1.12 Conclusion
References
Chapter 2: Physics of Laser-Matter Interaction in Laser-Based Manufacturing
2.1 Terminology
2.2 Energy Levels and Transitions
2.2.1 Electronic Levels
2.2.2 Vibrational Levels
2.2.3 Rotational Levels
2.3 Excitation
2.3.1 Stimulated and Spontaneous Emission
2.4 Population Inversions
2.5 Amplification and Oscillation
References
Chapter 3: Current Issues, Developments, and Constraints in Additive Manufacturing
3.1 Introduction
3.2 Fundamentals of AM
3.2.1 Process
3.2.2 Technique
3.2.3 Materials
3.2.4 Understanding the Requirements of Standards
3.3 Recent Trends
3.3.1 Hybrid Process
3.3.2 Micro Manufacturing
3.3.3 Process Optimization
3.3.4 4D Printing
3.3.5 Control and Monitoring
3.3.6 Data Acquisition
3.3.7 Sustainability
3.4 Applications
3.4.1 Biomaterials
3.4.2 Aerospace
3.4.3 Buildings
3.4.4 Protective Structures
3.4.5 Orthopedics
3.4.6 Repair and Remanufacturing of Damaged Components
3.4.7 AM for Space Resources
3.5 Limitations of AM
3.6 Conclusion
References
Chapter 4: Laser-Based Additive Manufacturing
4.1 Introduction
4.2 Laser in Additive Manufacturing
4.2.1 Classification of Laser-Based Additive Manufacturing
4.2.1.1 Polymer-Based Additive Manufacturing
4.2.1.2 Metal-Based Additive Manufacturing
4.2.2 Design for Additive Manufacturing Processes
4.2.3 Post-processing of Additive Manufactured Components
4.3 Defects in Laser-Based Additive Manufacturing Processes
4.4 Application of Laser-Based Additive Manufacturing Processes
4.4.1 Medical and Dental Applications
4.4.2 Automobile Application
4.4.3 Aerospace and Military Application
4.5 Comparison of Laser-Based Additive Manufacturing
4.6 Current Issues, Challenges, and Future Scope
Acknowledgement
References
Chapter 5: Prospects of AI and ML in Laser-Based Manufacturing Technologies
5.1 Introduction
5.2 Role of ML in LBM
5.2.1 DL-Based Predictive Visualization of Fiber Laser Machining
5.2.2 Using ML, the Effects of Laser Energy Uncertainty on Temperature Changes in Directed Energy Deposition
5.2.3 ML-Based Challenges
5.3 Role of AI in LBM
5.3.1 AI Challenges
5.4 Conclusion
References
Chapter 6: Application of Laser Technology in the Mechanical and Machine Manufacturing Industry
6.1 Introduction
6.1.1 Application of Lasers
6.1.1.1 In Defence Sector
6.1.1.2 In Telecommunication
6.1.1.3 In the Medical Industry
6.1.1.4 In the Manufacturing Industry
6.1.2 Advantages of Lasers
6.1.2.1 Extreme Precision
6.1.2.2 Automated
6.1.2.3 Energy Efficient
6.1.2.4 No Tool Wear
6.1.3 Limitations of Lasers
6.2 Current Tools and Techniques Used in Mechanical and Machine Industry
6.2.1 Laser Cutting, Drilling, and Piercing
6.2.1.1 Laser Cutting
6.2.1.2 Laser Drilling and Piercing
6.2.1.3 Limitations of the Existing Technology
6.2.1.4 Other Applications of Laser Cutting
6.2.2 Laser Welding
6.2.2.1 Typical Setup of Laser Welding
6.2.2.2 Applications of Laser Welding in General
6.2.2.3 Applications of Laser Welding in the Machine Industry
6.2.2.4 Limitations to the Existing Technology
6.2.3 Additive Manufacturing
6.2.3.1 Laser's Role in Additive Manufacturing
6.2.4 Various Techniques Used for Additive Manufacturing
6.2.4.1 Laser Powder Bed Fusion
6.2.4.1.1 Advantages of L-PBF
6.2.4.1.2 Applications of L-PBF
6.2.4.1.3 Limitations of the Existing Technology
6.2.4.1.4 Defects in the L-PBF Process
6.2.4.1.5 Geometry and Dimensional Defects
6.2.4.1.6 Defects Due to Weak Mechanical Properties
6.2.4.1.7 Microstructural Defects
6.2.4.1.8 Defects Due to Surface Quality and Integrity
6.2.4.2 Laser Engineered Net Shaping
6.2.4.2.1 Applications of LENS
6.2.4.2.2 Advantages of LENS
6.2.4.2.3 Limitations of the Existing Technology
6.2.4.3 VAT Photopolymerization
6.2.4.3.1 Steps Involved in the Process
6.2.4.3.2 Limitations of the Existing Technology
6.2.4.4 Sheet Lamination/Laminated Object Manufacturing
6.2.4.4.1 Applications of Laminated Object Manufacturing
6.2.4.4.2 Limitations to the Existing Technology
6.2.4.5 Two-Photon Polymerisation
6.2.4.5.1 Basic Physics Involved
6.2.4.5.2 Limitations to the Existing Technology
6.2.4.6 Layered Manufacturing Issues in General
6.2.4.7 Surface Treatment by Laser
6.2.4.7.1 Limitations of the Existing Technology
6.2.4.8 Laser Cleaning
6.2.4.8.1 Types of Laser Cleaning Techniques
6.2.4.8.2 Applications
6.2.4.8.3 Disadvantages of the Existing Technology
6.2.4.9 Medical Devices Manufactured Using Laser
6.2.5 Suitable Alternatives to Improve the Existing Technology
6.2.5.1 Laser Cutting
6.2.5.2 Laser Welding
6.2.5.3 Laser Drilling
6.2.5.4 Additive Manufacturing
6.2.5.5 For Surface Treatments
6.3 Summary, Conclusion, and Future Challenges
References
Chapter 7: Application of Laser-Based Manufacturing Processes for Aerospace Applications
7.1 Introduction
7.2 LAM, a Viable Option for the Fabrication of Aerospace Components
7.2.1 LAM processes
7.3 Laser Powder Bed Fusion
7.4 Laser-Directed Energy Deposition
7.5 Optimization of Parameters
7.6 Hybridization of the Process
7.7 Mitigation of Stresses
7.8 General Solutions to the Applications Through Findings
7.9 Conclusion
References
Chapter 8: Laser Micromachining in Biomedical Industry
8.1 Introduction
8.2 LMM and Texturing
8.2.1 Laser Systems
8.2.2 Applications in Biomedical Industry
8.3 Lasers and Materials LMM Devices
8.3.1 Materials for LMM Devices
8.3.1.1 Silicon
8.3.1.2 Polymers
8.3.1.3 Metals
8.3.1.4 Ceramics
8.3.1.5 Woods
8.3.1.6 Paper
8.3.1.7 Foams
8.3.1.8 Textiles
8.3.2 Common Industrial Lasers
8.3.2.1 Carbon Dioxide Lasers
8.3.2.2 Solid State Lasers
8.3.2.3 Fiber Lasers
8.3.2.4 Solid State Lasers in Medicines Today
8.3.3 System Considerations
8.3.4 Processing Considerations
8.4 Recent Trends in Biomedical Devices
8.4.1 Bio-Implants
8.4.2 Surgical Tools
8.4.3 Lab on Chip
8.4.4 Bio Sensors
8.4.5 Prosthetics
8.4.6 Angioplasty
8.4.7 AI and Computer Software
8.5 Challenges in Biomedical Industry and Solution for Future
8.6 Conclusion and Future Scope
References
Chapter 9: Effect of Laser Surface Melting on Atmospheric Plasma Sprayed High-Entropy Alloy Coatings
9.1 Introduction
9.2 Laser-Based Surface Modification Techniques
9.2.1 Laser Surface Texturing
9.2.2 Laser Cladding
9.2.3 Laser Shock Peening
9.2.4 Laser Surface Melting
9.2.5 Laser Hardening
9.2.6 Laser Surface Alloying
9.2.7 Laser Glazing
9.3 Laser-Material Interaction
9.4 Area of Applications
9.4.1 Automobile Applications
9.4.2 Aerospace Applications
9.4.3 Biomedical Applications
9.4.4 Nuclear Applications
9.5 High-Entropy Alloy
9.6 Experimental Procedure
9.7 Results and Discussion
9.8 Conclusions
9.9 Future Scope
Acknowledgments
References
Chapter 10: Laser Processing Technologies in Electronic and MEMS Packaging for Advancement of Industry 4.0
10.1 Introduction
10.1.1 Role of Sensors
10.1.2 Advancement
10.2 The Evolution of Biosensors
10.2.1 Essential Idea of Biosensors
10.2.2 Nano Materials
10.2.3 AI Biosensors
10.2.4 Flexible Bioelectronics Materials and Integration
10.2.5 Wireless Communication
10.2.6 Machine Learning
10.2.7 Smartphone-Based Platform
10.2.8 Designs in the Semiconductor Enterprises and Packaging Foundries
10.3 Laser Drilling
10.3.1 Laser Cutting
10.3.2 Accentuation
10.4 Conclusion and Future Scope
10.5 Future Scope
References
Index