SBPMat 2015 Sociedade Brasileira de Pesquisa em Materiais

Transcription

1 SBPMat 2015 Sociedade Brasileira de Pesquisa em Materiais Industrial Applications of Ultrafast Laser Surface Processing Alexandre Cunha, Ph.D. Post-doctorate Researcher Instituto SENAI de Inovação (ISI) em Laser, FIESC-SENAI / SC Director Edson Costa Santos, Ph.D. Pontifícia Universidade Católica do Rio Grande do Sul (PUCRS)

2 Why LIGHT matters? It revolutionizes the world Photonics Science & Technology Generating photons (Laser tech) Controlling photons Detecting photons Go toward the LIGHT

3 Outline Section 1 SENAI Innovation Institutes (ISIs) Section 2 Ultrafast Laser Surface Processing Section 3 Industrial Applications

4 Section 1 SENAI Innovation Institutes (ISIs) Section 2 Ultrafast Laser Surface Processing Section 3 Industrial Applications

5 What is the goal of the ISIs?

6 What industries?

7 ISIs in the Brazilian States

8 ISIs in the Santa Catarina State Laser Manufacturing systems Embedded systems Other SENAI Units SENAI Innovation Institutes Technology SENAI Institutes

9 ISIs in Manufacturing Systems and Laser Current facilities Area of 1,250 m 2 Future facilities Area of 8,000 m 2 Joinville-SC Industrial environment Metallurgy Plastics Information Tech Cultural environment Bolshoi Ballet Flowers festival

10 ISIs in Manufacturing Systems and Laser Manufacturing Systems Laser Manufacturing systems Materials Characterization Additive Manufacturing Welding Cutting Surface texturing

11 Additive manufacturing systems Selective Laser Melting (SLM) Laser Metal Deposition (LMD)

12 Surface texturing & drilling system Turnkey J Series workstation Industrial grade safety Three-color laser (IR / Vis / UV) Pulse duration: < 15 ps Rep. rate: 1 Hz khz High accuracy sample positioning High accuracy galvo heads Fully dedicated Cimita software Courtesy of Oxford Lasers, Didcot, England

13 National & international partners

14 Ongoing projects PROJECT 2014/ , PETROBRAS Implantation of the laser processing center with research development in coating, texturing, cutting and additive manufacturing processes PROJECT /2014-1, Ciências sem Fronteiras (CsF) Direct surface writing of metallic and ceramic materials using ultrafast lasers for dental and orthopedic implants

15 Section 1 SENAI Innovation Institutes (ISIs) in Manufacturing Systems and Laser Section 2 Ultrafast Laser Surface Processing Section 3 Industrial Applications

16 Why use laser technology? Contactless method No material contamination No coatings Material surface is directly modified Several types of materials Metals Semiconductors Polymers Laser technology Flexibility Direct laser writing Laser interferometry High processing speed mm/s m/s High reproducibility Precise control of the processing parameters

17 Why use ultrafast lasers? Long pulses Ultrashort pulses HAZ Recast Plasma plume Shockwaves Microcracking Debris Plasma plume HAZ Long pulses ( pulse > ns) Thermal ablation Melting & recast layer Significant HAZ 3.3 ns 200 fs Layer 1 Layer 2 Ultrashort pulses ( pulse ps) Cold ablation High energy density Rapid energy deposition Steel foil Negligible melting Negligible HAZ

18 Ultrafast laser surface texturing & drilling Direct laser writing setup 8 6 Industrial design Vorobyev, AY, et al. Laser Photonics Rev., 7(3), (2013) Courtesy of Oxford Lasers, Didcot, England

19 Ultrafast laser-induced surface textures Ultrafast laser pulses Wavelength Fluence Pulse shape Pulse duration Number of pulses Polarization Material Optical properties Thermophysical properties Mechanical properties Self-organized structures Holes Grooves Nanoscale Microscale Isotropic Anisotropic

20 Self-organized textures Surface texturing of Ti alloys LIPSS NPs MC 1 µm 1 µm 10 µm LIPSS: Laser-induced periodic surface structures NPs: Array of nano pillars MC: Array of micro columns 5 µm/div 5 µm/div Oliveira, V., et al. Applied Surface Science, 255, (2009) Oliveira, V., et al. Journal of Optoelectronics and Advanced Materials, 12(3), (2010)

21 Micro holes array & micro grooves Holes on 3D polymers 1-50 µm Grooves on polymers Different periods D Hole on Glass 120 μm Yong, J., et al. Journal of Materials Chemistry A, 2, (2014)

22 Section 1 SENAI Innovation Institutes (ISIs) in Manufacturing Systems and Laser Section 2 Ultrafast Laser Surface Processing Section 3 Industrial Applications

23 Surface texturing modifies the surface properties Surface Texturing Nano structures Micro structures Optical properties Tribological properties Wettability Cell behavior

24 Controlling the optical properties Structural colors on Ti alloys Control LIPSS Self-organized textures NPs MC LIPSS Structural colors on Al NPs MC Cunha, A. Multiscale femtosecond laser surface texturing of titanium and titanium alloys for dental and orthopaedic implants (2015) Nanostructure-textured microgrooves Vorobyev, AY, et al. Laser Photonics Rev., 7(3), (2013)

25 Total Reflectance (%) Enhancing the efficiency of solar cells Reflectance (%) Current (ma) Array of micro columns on Si (100) solar cells Micro structures induce multiple reflections of light Black Silicon Light gets entrapped between the surface features Laser Textured Silicon Control Laser Textured Silicon Wavelength (nm) Angle (Deg.) Voltage (V) Nayak, BK., et al. Progress in Photovoltaics: Research and Applications, 19, (2011)

26 Reducing friction in mechanical seals Mechanical seals Micro reservoir for lubricant Micro traps for wear debris CLASSICAL STRATEGY : Generation of an array of micro holes

27 Enhancing the lubrication conditions Micro topography of Ti-6Al-4V Reciprocal sliding tests LIPSS-textured surface 600 nm LSFL Bonse, J, et al. Applied Physics A. (2014) ADVANCED STRATEGY: Generation of self-organized structures

28 Enhancing the lubrication conditions LIPSS-textured surface of SiC seals 170 nm HSFL Water as lubricant Water as lubricant 20 % reduction Chen, CY, et al. Applied Physics A, 107, (2012)

29 Reducing the machining force of cutting tools Micro-grooves on uncoated cemented carbide tool 100 µm 200 µm Average values 300 µm 400 µm Width: 35 ± 3 µm Depth: 32 ± 6 µm Distance from the cutting edge of the rake face Barbosa, PA., et al. Lasers in Manufacturing Conference (2015)

30 Enhancing fuel injection efficiency and reducing emissions Diesel-injection nozzle drilling Diesel fuel filter drilling 50 µm Internal view of a drilled nozzle Hole < 100 µm Hole µm Micro holes 100 µm Brazilian Legislation Reducing emissions is mandatory between Courtesy of Oxford Lasers, Didcot, England

31 Load (kn) Enhancing the adhesive joint strength Array of micro columns on Steel and Ti Texture Control Texture Control A SIMILAR APPROACH WILL BE USED Ongoing project with a powerful Brazilian company Surface texturing of industrial valves for enhancing paint adhesion Elongation (mm) Baburaj, EG., et al. International Journal of Adhesion & Adhesives, 27, (2007)

32 Enhancing the surface wettability Anisotropic wetting on LIPSS CA degrees) Water wetting on Ti alloys Control NPs LIPSS Time (s) Cunha, A., et al. Applied Surface Science, 265, (2013) q CA (degrees) 120 q Texture orientation Droplet Droplet Observation direction Perpendicularly to LIPSS Parallelly to LIPSS Water HBSS Simulated biological fluids

33 Inducing self-cleaning properties Black Platinum Micro texture Nano texture Vorobyev, AY, et al. Journal of Applied Physics, 117, (2015)

34 Controlling the cell spreading & shape Human mesenchymal stem cells (hmscs) on Ti alloys Control LIPSS NPs F-actin fibers Cell nucleus Filopodia SPREADING STRETCHING FILOPODIA Cunha, A., et al. Nanomedicine (Lond.), 10(5), (2015)

35 F-actin fibres Cell nucleus Hydroxyapatite (HAp) Enhancing bone matrix mineralization Osteoblasts depositing bone matrix on Ti alloys Control LIPSS NPs Cunha, A., et al. Nanomedicine (Lond.), 10(5), (2015)

36 Relative Gene Expression (gene / 18s) Enhancing cell proliferation & osteoblast activity MSCs proliferation and differentiation on Ti alloys Control Texture Alkaline Phosphatase Osteocalcin Bush, JR., et al. Journal of Biomedical Materials Research Part B, 97B, (2011)

37 Reducing bacteria adhesion & biofilm Carboxyfluorescein succinimidyl ester S. aureus adhesion on Ti alloys Control LIPSS NPs S. Aureus Biofilm Cunha, A., et al. Applied Surface Science, under revision (2015)

38 Producing microfluidic circuits Complex structures on transparent materials Fluidic circuit Micro channel Glass Fused Silica Sapphire Micro pocket Courtesy of Oxford Lasers, Didcot, England

39 Final remarks Ultrafast laser technology is Reliable Precise Flexible It allows the creation of different Self-organized structures Holes Grooves Laser-induced surface textures may modify and control Optical properties Tribological properties Wettability Cell behavior Laser textured or drilled surfaces may find applications Oil & gas Automotive & aerospace Biomedical Energy

40 Collaborators Edson Costa Santos, Ph.D. Roberto Hübler, Prof. Ph.D. José da Silva Rabelo Neto, Ph.D. José Mário Fernandes de Paiva Júnior, Ph.D.

41 Thank you all for your attention