Article
Chemistry, Physical
Avik Samanta, Wuji Huang, Martell Bell, Scott K. Shaw, Nicholas Charipar, Hongtao Ding
Summary: An innovative laser-assisted functionalization method is proposed to fabricate a superhydrophobic-superhydrophilic patterned surface on a large-area metal alloy, with two different strategies demonstrated. Adjusting laser parameters allows for surface topography patterning and anti-reflection surface properties to be achieved. This method decouples extreme wettability from surface topography, showing simplicity, robustness, and feasibility.
APPLIED SURFACE SCIENCE
(2021)
Article
Materials Science, Multidisciplinary
S. Olivernesaraj, Prabhu Sethuramalingam
Summary: Laser texturing offers significant advantages over traditional texturization in design, quality, and flexibility. This study shows that nanosecond fiber laser textured surfaces with different patterns have a substantial impact on optical characteristics, resulting in higher light trapping efficiency.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2023)
Article
Engineering, Manufacturing
Ya-Zhou Mao, Jian-Xi Yang, Jin-Chen Ji
Summary: The study investigated the effects of different parameters on the surface texture of laser micropits, finding that higher power density and narrower pulse widths lead to more intense melting and splashing, while compressive stress and thermal stress are key factors in damage and diameter expansion. The research also revealed the generation of oxides and gradual decrease in energy distribution during laser machining process.
ADVANCES IN MANUFACTURING
(2021)
Article
Multidisciplinary Sciences
Yanming Zhang, Zhen Zhang, Yi Zhang, Denghua Liu, Jie Wu, Yu Huang, Guojun Zhang
Summary: Magnetic controlled laser induced plasma micro-machining (MC-LIPMM) can effectively improve the machining characteristics of silicon materials, while cavitation bubbles show an apparent negative impact on surface morphology.
JOURNAL OF ADVANCED RESEARCH
(2021)
Article
Materials Science, Multidisciplinary
Amr Salem, Hussien Hegab, Hossam A. Kishawy
Summary: Dry machining is an ideal strategy for eliminating the environmental and human health burdens of machining processes. This study investigated the effects of micro-textured cutting tools on cutting AISI 1045 steel and confirmed that careful design of micro-textured tools can improve overall machining performance.
Article
Engineering, Manufacturing
Wuji Huang, Avik Samanta, Hongtao Ding
Summary: The issue of global freshwater scarcity has become increasingly urgent due to the intensification of climate change effects. Fog harvesting has emerged as a sustainable and promising solution, and wettability-patterned surfaces have shown potential in enhancing fog harvesting efficiency. In this study, venation-like surface wetting patterns were directly fabricated on an aluminum alloy using a laser-assisted functionalization method. The resulting patterns demonstrated a significant increase in fog harvesting capability compared to the untreated surface.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Review
Engineering, Industrial
Alisson R. Machado, Leonardo R. R. da Silva, Felipe C. R. de Souza, Rahul Davis, Leandro C. Pereira, Wisley F. Sales, Wagner de Rossi, Emmanuel O. Ezugwu
Summary: This paper reviews recent research on the application of surface texturing in machining processes, highlighting the influencing parameters and common implementation methods to guide future related studies.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Weicheng Liu, Zhiwen Wang, Wei Yuan, Wentao Tian, Xuhui Sun, Chengjin Wang, Ali Naderi Bakhtiyari, Jianchen Cong, Hongyu Zheng
Summary: This study utilized a picosecond laser to create micro-textures on ductile iron, enhancing processing efficiency and tribological properties. By correlating laser processing parameters with tribological properties of ductile iron, the research established simulation models based on the Reynold equation to understand the wear reduction mechanism of micro-dimples. The results showed that the generation of graphene micro-textures through laser processing effectively enhanced the tribological properties of the ductile iron surface.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Optics
Hongchao Qiao, Cao Zhihe, Cui Jianfeng, Jibin Zhao
Summary: Water jet guided laser micro-machining is a novel technique for micro-machining hard brittle materials, achieving high aspect ratio and kerf edge variations, particularly effective for cutting monocrystalline silicon.
OPTICS AND LASER TECHNOLOGY
(2021)
Article
Chemistry, Analytical
Tatsuhiko Aizawa, Tomoaki Yoshino, Yohei Suzuki, Tadahiko Inohara
Summary: A new data transformation method for micro-manufacturing using a topological model for a micro-/nano-texture is proposed in this study. The method utilizes femtosecond laser printing and plasma nitriding to create customized textures on metallic products.
Article
Chemistry, Physical
Si Li, Yangyang Jin, Shaoxian Bai, Jing Yang
Summary: This study investigates the effects of the electrostatic force on the growth and adhesion of osteoblast cells on laser-ablated textured surfaces. The results show that the electrostatic force not only enhances the hydrophilicity of the surface but also guides cells to attach at the edges and corners of the textured surface. This findings suggest that the electrostatic force plays a crucial role in improving the bioactivity of the surfaces.
Article
Engineering, Mechanical
Suryank Dwivedi, Amit Rai Dixit, Alok Kumar Das, Ashish Kumar Srivastava
Summary: This study introduces a mechanical indentation method to develop and characterize pyramid-shaped micro-texturing on biomedical grade SS 316L. The results show that the micro-textures are formed in a periodic manner and the textured surface presents increased hydrophilicity.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2023)
Article
Chemistry, Physical
Jian Chen, Adrian S. Sabau, Harry Meyer, Donovan Leonard
Summary: After exposure to high-energy laser pulses, Ti6Al4V specimens showed periodic surface textures due to laser-interference and microstructural changes. XPS analysis demonstrated effective removal of surface contaminants and formation of oxy-nitride layer on the laser treated material. Microstructure analysis revealed grain refinement, dendrite, and twin structures near the surface as a result of laser processing.
APPLIED SURFACE SCIENCE
(2021)
Article
Chemistry, Multidisciplinary
Matteo Mastellone, Alessandro Bellucci, Marco Girolami, Valerio Serpente, Riccardo Polini, Stefano Orlando, Antonio Santagata, Elisa Sani, Frank Hitzel, Daniele M. Trucchi
Summary: This study demonstrates, for the first time, the achievement of two-dimensional laser-induced periodic surface structures with deep-subwavelength periodicity on diamond surfaces. The method involves using two temporally delayed and cross-polarized femtosecond-laser pulses to achieve distinctive nanotexturing, which can be controlled by varying the number of pulses. The effective treatment of large areas of diamond surfaces under scanning mode leads to significantly enhanced absorptance in the visible range, paving the way for the development of metasurfaces for future diamond-based optoelectronic devices.
Article
Engineering, Manufacturing
Adrian H. A. Lutey, Gianmarco Lazzini, Laura Gemini, Alexander Peter, Volkher Onuseit, Javier Graus, Francesco Fuso, Rainer Kling, Luca Romoli
Summary: Detailed analysis and characterization of injection-molded polypropylene specimens produced with laser-textured molds shows good replication effectiveness, especially for surface morphologies with LIPSS oriented parallel to the injection direction. However, attention must be paid to the size and nature of defects for specific functional surfaces.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Instruments & Instrumentation
Samantha Webster, Marco Giovannini, Yi Shi, Nicolas Martinez-Prieto, Kamel Fezzaa, Tao Sun, Kornel Ehmann, Jian Cao
Summary: Laser metal additive manufacturing is a popular technology due to its versatility in geometry and materials. Powder-blown directed energy deposition (DED) is a widely used additive process in industries such as aerospace, automotive, and medical device. However, there is still a lack of fundamental understanding and opportunities for alloy development and implementation. This study presents a high-throughput, in situ DED system capable of multi-layer builds, investigating the implications of layer heights and energy density and discussing multi-layer interactions.
REVIEW OF SCIENTIFIC INSTRUMENTS
(2022)
Article
Engineering, Industrial
Zilin Jiang, Kornel F. Ehmann, Jian Cao
Summary: This study proposes an artificial neural network (ANN) framework for predicting the forming temperature in electrically-assisted double-sided incremental forming (EA-DSIF). The ANN model uses measurements of surrounding temperature and toolpath features to accurately predict the forming temperature. The model was trained using temperature outputs from finite element models and its feasibility was validated through experiments.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2022)
Article
Engineering, Industrial
Mojtaba Mozaffar, Shuheng Liao, Xiaoyu Xie, Sourav Saha, Chanwook Park, Jian Cao, Wing Kam Liu, Zhengtao Gan
Summary: This study reviews recent advances in Mechanistic-AI in the field of manufacturing, introducing the benefits of this methodology and approaches to improve data requirements, generalizability, and explainability. It also identifies gaps in current research and directions for further development.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2022)
Article
Chemistry, Physical
Lichao Fang, Lin Cheng, Jennifer A. Glerum, Jennifer Bennett, Jian Cao, Gregory J. Wagner
Summary: Accurately predicting the temperature field is crucial in additive manufacturing of metal parts. In this study, a finite element simulation and machine learning methods were used to predict the temperature field during the construction process of Inconel 718 walls, and the relationship between temperature field and material properties was investigated.
NPJ COMPUTATIONAL MATERIALS
(2022)
Article
Chemistry, Physical
Tianju Xue, Zhengtao Gan, Shuheng Liao, Jian Cao
Summary: The phase-field method is a computational approach for simulating interfacial morphology in material additive manufacturing. Traditional direct numerical simulation is time-consuming, but the physics-embedded graph network method provides a faster solution while preserving key physical features.
NPJ COMPUTATIONAL MATERIALS
(2022)
Article
Mathematics, Interdisciplinary Applications
Shuheng Liao, Tianju Xue, Jihoon Jeong, Samantha Webster, Kornel Ehmann, Jian Cao
Summary: Understanding the thermal behavior of additive manufacturing processes is crucial for quality control and process design. This study develops a hybrid physics-based data-driven thermal modeling approach using physics-informed neural networks. The results demonstrate the effectiveness of the model in identifying unknown parameters and accurately capturing the full-field temperature, making it suitable for iterative process design and real-time process control of additive manufacturing.
COMPUTATIONAL MECHANICS
(2023)
Article
Mechanics
Orion L. Kafka, Cheng Yu, Puikei Cheng, Sarah J. Wolff, Jennifer L. Bennett, Edward J. Garboczi, Jian Cao, Xianghui Xiao, Wing Kam Liu
Summary: This study investigates the tensile properties of nickel-based alloy IN718, focusing on the spatial and orientation-based differences. The researchers used in-situ x-ray computed tomography to observe the internal pore populations and measured the evolution of pore shape during deformation. The results were compared to simulations using a computational crystal plasticity scheme, providing insights into the grain orientation in which the pore resides. The measurements show that pores tend to grow and elongate in the direction of loading, consistent with ductile deformation, and do not cause premature failure.
INTERNATIONAL JOURNAL OF SOLIDS AND STRUCTURES
(2022)
Article
Engineering, Manufacturing
Mojtaba Mozaffar, Shuheng Liao, Jihoon Jeong, Tianju Xue, Jian Cao
Summary: This paper presents a differentiable simulation method for optimizing the thermal behavior of materials in additive manufacturing processes. By using automatic differentiation to compute gradients, high-dimensional design spaces can be handled. The methodology is validated through experimental testing.
ADDITIVE MANUFACTURING
(2023)
Article
Engineering, Industrial
Shuheng Liao, Jihoon Jeong, Rujing Zha, Tianju Xue, Jian Cao
Summary: A simulation-guided feedforward-feedback control framework is developed for effective control of the melt pool temperature in additive manufacturing processes. The experimental results demonstrate that the feedforward-feedback control method significantly improves control performance compared to conventional feedback control.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Industrial
Fred M. Carter III, Dominik Kozjek, Conor Porter, Samuel J. Clark, Kamel Fezzaa, Makoto Fujishima, Naruhiro Irino, Jian Cao
Summary: A co-axial photodiode monitoring system with high temporal resolution has been integrated into a proven test bench, allowing for synchronized side-view high-speed X-ray imaging for observing melt pool dynamics and top-view spectral emission characterization of the melt pool. The correlation between these two monitoring systems can be directly scaled to commercial systems. The study shows a 92% detection rate of keyhole collapse phenomena related to defect generation in selective laser melting (SLM), as well as investigates the impact of gas flow on monitoring signals to understand its fundamental importance in commercial systems.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Industrial
Guido Tosello, Giuliano Bissacco, Jian Cao, Dragos Axinte
Summary: This paper presents the state-of-the-art in modeling and simulation of surface texture and topography generation at micro and nano scales. It reviews three main manufacturing processes for surface generation and discusses various modeling techniques. The application of these techniques in predicting surface characteristics and geometry are presented, along with a roadmap for a complete surface generation digital twin in manufacturing.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2023)
Article
Mathematics, Interdisciplinary Applications
Shuheng Liao, Ashkan Golgoon, Mojtaba Mozaffar, Jian Cao
Summary: This paper presents a method for rapid thermomechanical simulation of metal additive manufacturing using a fully vectorized implementation on graphical processing units. The method utilizes implicit time discretization and the finite element method, solving the incremental elastoplastic problem using the conjugate gradient method. Sparse representation of algorithmic (tangent) stiffness matrix and the strain-displacement operator are used. The GPU implementation is 10-25x faster than the CPU version, enabling fast prediction of residual stress in additive manufacturing to improve process design effectiveness and avoid process defects.
COMPUTATIONAL MECHANICS
(2023)
Article
Engineering, Industrial
Clayton Cooper, Jianjing Zhang, Joshua Huang, Jennifer Bennett, Jian Cao, Robert X. Gao
Summary: This research explores a data-driven predictive model with Shapley additive explanation (SHAP) to improve the accuracy and interpretability of predicting mechanical properties in directed energy deposition (DED) processes. The results demonstrate that by interpreting input features and reducing model complexity, both the accuracy and effectiveness of predictive models for Inconel 718 (IN718) tensile strength can be improved.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
Article
Computer Science, Interdisciplinary Applications
Tianju Xue, Shuheng Liao, Zhengtao Gan, Chanwook Park, Xiaoyu Xie, Wing Kam Liu, Jian Cao
Summary: This paper introduces JAX-FEM, an open-source differentiable finite element method (FEM) library that is implemented with pure Python and scalable for solving moderate to large problems. It achieves significant acceleration compared to commercial FEM codes and enables automatic solving of inverse problems. JAX-FEM also serves as an integrated platform for machine learning-aided computational mechanics.
COMPUTER PHYSICS COMMUNICATIONS
(2023)
Article
Multidisciplinary Sciences
Samantha Webster, Newell Moser, Kamel Fezzaa, Tao Sun, Kornel Ehmann, Edward Garboczi, Jian Cao
Summary: The use of metal additive manufacturing (AM) components is currently limited in industries due to process defects resulting in shorter fatigue life, potential catastrophic failure, and lower strength. Scientists have started analyzing the conditions and mechanisms of these defects to improve reliability and structural integrity of these highly customized parts.
