TE136/2018 Project
English (Engleză)
Project number: PN-III-P1-1.1-TE-2016-2015
Project title: Laser welding of aluminium based metal matrix nanocomposite under high speed imaging and spectroscopic monitoring
Financial support:
Romanian National Authority for Scientific Research and Innovation, CNCS-UEFISCDI
Periode: October 2018 - December 2020
Contact Person:
Project Director: Dr. Eng. Andrei Popescu
Coordinator:
National Institute for Laser, Plasma and Radiation Physics - I.N.F.L.P.R.
Atomiștilor 409, Măgurele, Romania
Objectives:
Main goals
O1. Optimization of parameters process for obtaining the best conditions for monitoring the irradiated area and the ablation plume.
O2. Systematic study of the laser welding method under real-time monitoring.
O3. Welds analysis by physicochemical techniques.
O4. Functional tests.
Phases and activities:
Phase I
Period: 2 months
Activities:
-Set up the experimental assembly
-Preliminary laser welding tests
During this stage we performed preliminary laser welding tests of aluminium samples. This material will constitute the matrix of the composite that will be used further on. These preliminary tests will serve as control experiments in order to compare the quality of the laser welding on ordinary aluminium with Aluminium Matrix Composites (AMC) welds.
Phase II
Period:12 months
Activities:
-Welding of Aluminum Matrix Composites: commercial AlMg3, AlMg5 and AlMg5 with dispersed phase of Al2O3, produced in the laboratory using metallurgy powder.
-Study of the effect of process parameters.
- Optical microscopy of samples before and after laser welding.
- Mechanical tests.
In this stage of the project we analyzed in detail the possibility of welding Alumninium Matrix Composite. The effect of laser power, incline angle of the processing head, velocity, defocus and the influence of the shielding gas was analyzed. The limitations of the method and the problems that can occur in the interaction between high power laser pulses and AMC materials was established.
Phase III
Period: 11 months
Activities:
- High speed imaging studies in order to corelate the welding defects with plasma plume.
In this stage of the project our main goal was to correlate the appearance of pores with the area/ intensity of the plasma plume, in order to create a mechanism to find in real time the defects during laser welding of AMC. Different samples produced with optimal conditions previously established were analyzed using high speed imaging. The research team selected different zones of the plasma plume in order to obtain accurate information. It was observed that relevant data can be extracted from global monitoring or the maximum intensity of the plasma plume area.
Estimated results:
- Identification of the best welding conditions for obtaining mechanical resistance comparable to standards.
- Drastic diminution of welding defects.
- Identification of optimal conditions (luminance, signal/noise ratio, peak intensity, filters) for acquiring signals for fast processing and automation.
- 3 ISI papers
- 3 oral communications and posters at International Conferences
• PhD student Georgiana Chioibasu
• PhD student Raluca Ivan
• Dr. George Stan
• Dr. Camelia Popescu
• Dr. Liviu Duta
Română (Romanian)
Numar proiect: PN-III-P1-1.1-TE-2016-2015
Titlul proiectului: Sudura laser monitorizata prin imagistica rapida si spectroscopie optica a unor materiale nanocomposite cu matrice metalica de aluminiu
Suport financiar:
Autoritatea Nationala Romana pentru Cercetare Stiintifica si Inovare, CNCS-UEFISCDI
Perioada: Octombrie 2018 - Decembrie 2020
Persoana de contact:
Director Proiect: Dr. Ing. Andrei Popescu
Coordonator:
Institutul Național pentru Fizica Laserilor, Plasmei și Radiației - I.N.F.L.P.R.
Atomiștilor 409, Măgurele, ROMÂNIA
Obiective:
Obiectivul principal al acestui proiect este de a realiza sudura unor materiale compozite cu matrice metalica (MMC) ce contin faza dispersata micronica utilizand surse laser si de a obtine imbunatatiri semnificative, care vor incadra sudura laser in categoria tehnicilor viabile pentru procesarea acestor tipuri de materiale. In acest scop se vor folosi diferite surse laser cu lungimi de undă și durata a impulsului variabile, se va monitoriza procesul prin spectroscopie optica, imagistica si se va efectua un studiu amanuntit fizico-chimic si metalurgic al sudurilor. In timpul derularii proiectului vor fi testate tehnici noi precum: utilizarea de fascicule laser cu impulsuri foarte scurte, utilizarea de fascicule defocalizate de energie joasa pe substraturi subtiri de MMC, teste cu racire rapida a zonei procesate, utilizarea de concentratii scazute de faza dispersata in scopul diminuării fenomenelor de aglomerare.
Obiectivele principale
O1. Optimizarea parametrilor de process in vederea obtinerii celor mai bune conditii pentru monitorizarea zonei iradiate si a plasmei.
O2. Studiul sistematic al metodei de sudare cu laserul prin monitorizare în timp real.
O3. Analiza fizico-chimica a materialelor procesate cu laserul.
O4. Teste functionale.
Etape și activități prevăzute:
Etapa I
Perioada: 2 luni
Activitati:
- Realizarea montajului experimental;
- Teste preliminare de sudura laser a unor esantioane de aluminiu
In prima etapa am realizat teste preliminare de sudura laser a unor esantioane de aluminiu, material care va fi matricea compozitelor pe care le vom studia in acest proiect. Aceste teste vor servi ca si experimente de control cu care vom compara in etapa viitoare rezultatele obtinute pe compozite cu matrice de aluminiu (AMC).
Etapa II
Perioada:12 luni
Activitati:
- Sudarea materialelor compozite cu matrice metalica pe baza de aluminiu: AlMg3 comercial, AlMg5 si AlMg5 cu faza dispersata de Al2O3 produse in laborator prin metalurgia pulberilor.
-Studiul parametrilor de process.
- Microscopie optica a esantioanelor inainte si dupa sudarea laser.
- Teste mecanice.
In aceasta faza de proiect am analizat in detaliu posibilitatea sudarii materialelor compozite cu matrice metalica pe baza de aluminiu, analizand efectul puterii laser, al unghiului de inclinare al opticii de procesare, al vitezei de translatie, a gradului de focalizare si influenta gazului protector. In acest fel am dorit sa aflam limitarile metodei si problemele care pot aparea la interactia dintre impulsurile laser de mare putere si materialele AMC.
Etapa III
Perioada:11 luni
Activitati:
- Studii in extenso de imagistica rapida in vederea stabilirii corelatiilor dintre plasma laser si defectele sudurilor.
In aceasta faza de proiect, principalul obiectiv a fost corelarea aparitiei porilor cu anumite caracteristici ale norului de plasma, astfel incat sa putem monitoriza in timp real aparitia defectelor de sudura. Au fost analizate mai multe probe procesate cu laserul pastrand conditiile de procesare stabilite ca fiind optime in etapa anterioara a proiectului. Echipa de cercetare a monitorizat mai multe zone ale norului de plasma de diferite intensitati in scopul de a obtine date cat mai precise. S-a observat ca se pot extrage informatii relevante atat din monitorizarea globala a ariei norului de plasma, cat si a zonei de intensitate maxima din centrul acestuia.
Rezultate estimate:
- Identificarea celor mai bune conditii de sudura pentru obtinerea unor rezistente conforme standardelor
- Reducerea drastica a defectelor de sudura
- Identificarea conditiilor optime (luminanta, raport semnal/zgomot, intensitatea peak-urilor, filtre) pentru a achizitiona semnale pentru procesare rapida si automatizare
- 3 articole ISI
- 3 comunicari orale si postere la Conferinte internationale
• Doctorand Georgiana Chioibasu
• Doctorand Raluca Ivan
• Dr. George Stan
• Dr. Camelia Popescu
• Dr. Liviu Duta
Publications:
[1] Mahmood, M.A.; Popescu, A.C.; Mihailescu, I.N., “Metal Matrix Composites Synthesized by Laser-Melting Deposition: A Review”, Materials 2020, 13, 2593.
[2] Bucă, A.M.; Oane, M.; Mahmood, M.A.; Mihăilescu, I.N.; Popescu, A.C.; Sava, B.A.; Ristoscu, C., “Non-Fourier Estimate of Electron Temperature in Case of Femtosecond Laser Pulses Interaction with Metals”, Metals 2020, 10, 606.
[3] Mahmood, M.A.; Popescu, A.C.; Oane, M.; Ristoscu, C.; Chioibasu, D.; Mihai, S.; Mihailescu, I.N., “Three-Jet Powder Flow and Laser–Powder Interaction in Laser Melting Deposition: Modelling Versus Experimental Correlations”, Metals 2020, 10, 1113.
[4] Muhammad Arif Mahmood, Andrei C. Popescu, Claudiu Liviu Hapenciuc, Carmen Ristoscu, Anita Ioana Visan, Mihai Oane , Ion N. Mihailescu , “Estimation of clad geometry and corresponding residual stress distribution in laser melting deposition: analytical modeling and experimental correlations”, Int J Adv Manuf Technol 2020, 111, 77–91
[5] Chioibasu, D.; Mihai, S.; Mahmood, M.A.; Lungu, M.; Porosnicu, I.; Sima, A.; Dobrea, C.; Tiseanu, I.; Popescu, A.C., “Use of X-ray Computed Tomography for Assessing Defects in Ti Grade 5 Parts Produced by Laser Melting Deposition”, Metals 2020, 10, 1408.
[6] Duta, L.; Neamtu, J.; Melinte, R.P.; Zureigat, O.A.; Popescu-Pelin, G.; Chioibasu, D.; Oktar, F.N.; Popescu, A.C., “In Vivo Assessment of Bone Enhancement in the Case of 3D-Printed Implants Functionalized with Lithium-Doped Biological-Derived Hydroxyapatite Coatings: A Preliminary Study on Rabbits”, Coatings 2020, 10, 992.
[7] E. P. Florian, L. Duta, V. Grumezescu, G. Popescu-Pelin, C. Popescu, N. F. Oktar, W. R. Evans, A. Roseanu Constantinescu, "Lithium-Doped Biological-Derived Hydroxyapatite Coatings Sustain In Vitro Differentiation of Human Primary Mesenchymal Stem Cells to Osteoblasts", Coatings 2019, 9, 781.
[8] L. Duta, A.C. Popescu, "Current Status on Pulsed Laser Deposition of Coatings from Animal-Origin Calcium Phosphate Sources", Coatings 2019, 9, 335.
[9] D. Chioibasu, A. Achim; C. Popescu, G. E. Stan, I. Pasuk, M. Enculescu, S. Iosub, L. Duta, A. C. Popescu, „Prototype Orthopedic Bone Plates 3D Printed by Laser Melting Deposition”, Materials 2019, 12, 906.
[10] D. Chioibasu, L. Duta, G. Pelin-Popescu, N. Milodin, N. Popa, S. Orobeti, L. M. Balescu, A. C. Galca, A. C. Popa, F. N. Oktar, G. E. Stan, A. C. Popescu, „Bioactive natural hydroxyapatite thin films synthesized by RF-Magnetron Sputtering on 3D printed cranial prostheses”, Metals 2019, 9 (12), 1332
Conference presentations:
[1] Sabin MIHAI, Diana CHIOIBASU, Andrei C. POPESCU, “METALLIC IMPLANTS 3D PRINTED BY ADDITIVE MANUFACTURING” EmergeMAT 3RD INTERNATIONAL CONFERENCE ON EMERGING TECHNOLOGIES IN MATERIALS ENGINEERING, 29-30 October 2020, Bucharest
[2] Diana CHIOIBASU , Sabin MIHAI , Muhammad Arif MAHMOOD , Ion TISEANU, Mihail LUNGU, Ioana POROSNICU, Andrei C. POPESCU, “POROSITY CHARACTERIZATION OF SAMPLES 3D PRINTED BY LASER MELTING DEPOSITION USING X-RAY COMPUTER TOMOGRAPHY, EmergeMAT 3RD INTERNATIONAL CONFERENCE ON EMERGING TECHNOLOGIES IN MATERIALS ENGINEERING”, 29-30 October 2020, Bucharest,
[3] Muhammad Arif Mahmood, Andrei C. Popescu, Mihai Oane, Carmen Ristoscu, Diana Chioibasu, Sabin Mihai , Ion N. Mihailescu , “3-JET POWDER FLOW AND LASER-POWDER INTERACTION IN LASER MELTING DEPOSITION: MODELLING VERSUS EXPERIMENTAL CORRELATIONS, EmergeMAT 3RD INTERNATIONAL CONFERENCE ON EMERGING TECHNOLOGIES IN MATERIALS ENGINEERING”, 29-30 October 2020, Bucharest, Romania
[4] D. Chioibasu, A. C. Popescu, “Prototype cranial mesh prostheses produced by laser additive manufacturing”, E-MRS 2019 Spring Meeting, Nisa, Franta, oral presentation
[5] A. C. Popescu, D. Chioibasu, M. Leparoux, “High speed imaging monitoring of molten pool and spatter produced during laser processing of metal matrix nanocomposites”, E-MRS 2019 Spring Meeting, Nisa, Franta, oral presentation
[6] D. Chioibasu, “Removal of excessive spatter generated during laser welding of metal matrix nanocomposites”, International Conference on Renewable Energy and Energy Conversion (ICREEC 2019), Oran, Algeria, oral presentation
[7] A. C. Popescu, “Additive technologies for production and processing of metallic implants”, International Conference on Renewable Energy and Energy Conversion (ICREEC 2019), Oran, Algeria, invited presentation
Patents:
[1] Diana CHIOIBASU, Sabin MIHAI, Raluca IVAN, Andrei C. POPESCU, “Disc de frână acoperit cu un strat metalic pentru protecție la coroziune și uzură și metodă de obținere a acestuia”, A/00550/ 02.09.2020
[2] Diana CHIOIBASU, Sabin MIHAI, Liviu DUTA, Andrei C. POPESCU, “Tehnologie de fabricație aditivă a unor dispozitive de fixare pentru implanturi metalice prin metoda Depunere Laser prin Topire” A/00214/22.04.2020