Porosity in laser powder bed fusion (LPBF) additive manufacturing significantly affects the mechanical properties and performance of produced parts. Traditional volumetric energy density (VED) model has limitations in accurately predicting porosity, as it does not account for material-specific properties and thermal dynamics. This study investigates a comparative analysis of porosity formation in LPBF of AISI 316L stainless steel through experiments, finite element (FE), and analytical models. In the case of analytical model, a modified VED (MVED) relationship is proposed, incorporating material properties and thermo-physical characteristics to address the shortcomings of conventional VED approaches. LPBF experiments were conducted to print the samples by varying process parameters, and X-ray computed tomography was utilized to characterize the porosity within the fabricated samples. FEM simulations were also conducted to predict thermal distributions, melt pool dimensions and corresponding porosity. It was found that the MVED analytical model demonstrated improved empirical correlation with experimental porosity compared to the traditional VED, with an R-squared value of 0.88 versus 0.75 for the traditional model. This improvement highlights the importance of considering material-specific properties in energy density calculations. FEM results showed good agreement with experimental observations of porosity trends across different processing conditions, accurately predicting thermal distributions and melt pool dimensions. The presented approach provides insights into porosity formation mechanisms and offers potential for optimizing LPBF processing parameters to minimize defects, while addressing the limitations of traditional VED models.

The Pennes bioheat equation is the most widely used model for describing heat transfer in living tissue during thermal exposure. It is derived from the classical Fourier law of heat conduction and assumes energy exchange between blood vessels and surrounding tissues. The literature presents various numerical methods for solving the bioheat equation, with exact solutions developed for different boundary conditions and geometries. However, analytical models based on this framework are rarely reported. This study aims to develop an analytical three-dimensional model using MATHEMATICA software, with subsequent mathematical validation performed through COMSOL simulations, to characterize heat transfer in biological tissues induced by laser irradiation under various therapeutic conditions. The objective is to refine the conventional bioheat equation by introducing three key improvements: (a) incorporating a non-Fourier framework for the Pennes equation, thereby accounting for the relaxation time in thermal response; (b) integrating Dirac functions and the telegraph equation into the bioheat model to simulate localized point heating of diseased tissue; and (c) deriving a closed-form analytical solution for the Pennes equation in both its classical (Fourier-based) and improved (non-Fourier-based) formulations. This paper investigates the nuanced relationship between the relaxation time parameter in the telegraph equation and the thermal relaxation time employed in the bioheat transfer equation. Considering all these aspects, the optimal thermal relaxation time determined for these simulations was 1.16 s, while the investigated thermal exposure time ranged from 0.01 s to 120 s. This study introduces a generalized version of the model, providing a more realistic representation of heat exchange between biological tissue and blood flow by accounting for non-uniform temperature distribution. It is important to note that a reasonable agreement was observed between the two modeling approaches: analytical (MATHEMATICA) and numerical (COMSOL) simulations. As a result, this research paves the way for advancements in laser-based medical treatments and thermal therapies, ultimately contributing to more optimized therapeutic outcomes.

A strongly coupled quasi-two-dimensional dusty plasma confined electrostatically in the plasma sheath of a radio frequency (RF) plasma is irradiated by a collimated and mono-energetic pulsed electron beam (e-beam) with an energy of 13 keV and a high peak current per pulse of 30 mA. A stream of rapidly moving charged dust particles is created inside the dust crystal due to the drag force of the electrons in the e-beam. The dust flow is split into two symmetrical branches when it reaches the boundary of the round dust crystal, each following the limit of the circular confining region. This results in the formation of a double vortex flow pattern with the dust particles being transported along the irradiation direction and then aside, eventually back to the entrance position of the e-beam. The observed flow regime is laminar at all times, with the speed in the central region increasing up to 12 mm s(-1) in the first 200 ms and then diminishing gradually to a steady value of about 5-6 mm s(-1) during a stress relaxation time period of 360 ms. The vorticity follows a similar trend with peak values -3.8 and 3.8 s(-1) and steady state values between -2.5 and 2.5 s(-1) in the two symmetrical vortices. Time-resolved particle-image-velocimetry and particle-tracking-velocimetry are used to characterize the flow. Molecular dynamics simulations confirm qualitatively the experimental observations showing dust stream and double vortex formation. (c) 2024 Author(s). All article content, except where otherwise noted, is licensed under a Creative Commons Attribution-NonCommercial-NoDerivs 4.0 International (CC BY-NC-ND) license (https://creativecommons.org/licenses/by-nc-nd/4.0/)

Additive manufacturing (AM) has profoundly impacted modern engineering and materials science by enabling unparalleled control over microstructures, customization, and material properties [...]

Austenitic stainless steel, also known as SUS304, has a wide industrial application. The resultant residual stresses and deformation due to arc welding play a critical role in an in-service SUS04 part failure. Various experimental studies have been presented to predict residual stresses and part deformation. However, these techniques are expensive and time-consuming owing to the trial-and-error approach, limiting their application to industrial applications. Based on the emergent need, this study introduces two simulation models based on analytical and FEM techniques for thermal distribution and residual stress estimation. The experimentally calibrated models results have been implemented for SUS304 multi-pass arc welding. For the analytical simulation framework, a thermal model by considering the arc torch energy attenuation has been solved and provided as an input to the residual stress distribution model solved using Green’s function technique. For FEM, a thermo-mechanical coupled model has been proposed and solved using the symmetrical technique. A close correlation has been identified among the analytical, FEM, and experimental techniques. It was found that during the second welding pass, a significant increase in the peak temperature was observed due to elevated arc-material interaction, leading to an expanded heat-affected zone and melt pool. Residual stress analysis highlighted the crucial role of thermal gradient and cooling mechanisms in generating stress within the weld region, which is essential for material strength assessment and failure prediction. This study offers a comprehensive understanding of the thermal and residual stress behaviors in multi-pass arc welding of SUS304 stainless steel bulk plates and can be applied to arc-based additive manufacturing processes.

Femtosecond laser pulses are currently regarded as an emerging and promising tool for processing wide bandgap dielectric materials across a variety of high-end applications, although the associated physical phenomena are not yet fully understood. To address these challenges, we propose an original, fully analytical model combined with Two Temperatures Model (TTM) formalism. The model is applied to describe the interaction of fs laser pulses with a typical dielectric target (e.g., Sapphire). It describes the heating of dielectrics, such as Sapphire, under irradiation by fs laser pulses in the range of (1012–1014) W/cm2. The proposed formalism was implemented to calculate the free electron density, while numerical simulations of temperature field evolution within the dielectrics were conducted using the TTM. Mathematical models have rarely been used to solve the TTM in the context of laser–dielectric interactions. Unlike the TTM applied to metals, which requires solving two heat equations, for dielectrics the free electron density must first be determined. We propose an analytical model to solve the TTM equations using this parameter. A new simulation model was developed, combining the equations for non-equilibrium electron density determination with the TTM equations. Our analyses revealed the non-linear nature of the physical phenomena involved and the inapplicability of the Beer–Lambert law for fs laser pulse interactions with dielectric targets at incident laser fluences ranging from 6 to 20 J/cm2.

An integrated approach combining finite element modelling, machine learning, and experimental verification was proposed for developing process maps to optimize the LPBF process for AlSi10Mg alloy. A transient thermal simulation model was validated to predict single-layer melt pool size by modifying laser beam power, scan rate, feedstock bed depth, and preheating of feedstock. Using the verified model, a pool of data was generated to develop a backpropagation neural network to predict melt pool dimensional ratios indicating printing defects. It was found that beyond process parameters, powder bed thickness and preheating temperature impacted defect formation. Excessively high preheating temperatures increased the lack of fusion defects by transforming melt pool dynamics from conduction to keyhole mode. Optimal combinations were identified as 30.0 μm thickness with 90.0 and 120.0 °C preheating and 50.0 μm thickness with 120.0 °C preheating. By reducing iterative physical testing, the integrated process mapping approach enables accelerated qualification of LPBF parameters for AlSi10Mg alloy.

A new experimental method using a 50 mu m diameter hand fabricated hot probe of Pt90/10Rh alloy is proposed as a tool to measure the Seebeck coefficient of thin films deposited onto electrically insulated substrates. A thermal model for heat transfer inside the probe and to the sample was developed to simulate the corresponding temperature distributions. Simulations showed that the ratio of the temperature rise in the contact point to the average temperature of the probe evolves basically independent on electrical current and film-substrate properties. Moreover, the values of contact radius and thermal contact resistance should not be necessary known, but only the pairs which are best fitting the probe thermal resistance in contact with the film-substrate. This brings a great simplification in respect with certain AFM based hot probe methods for which is necessary to determine these two parameters by calibration of the two substrates with known thermal conductivity. The values can be further used to evaluate the Seebeck coefficient of the sample with a macroscopic probe, within 1 % precision. By variance to the classical measuring methods, which resort to a heater-heat sink ensemble instrumented with thermocouples, heated metallic rods with built-in thermocouples or microfabricated structures, the proposed method is fast, reliable and of higher spatial resolution. The method was validated by measuring the Seebeck coefficient on CdS, Bi and Cr thin films reference samples, respectively.

The ultrafast fs laser pulse heating of thin metal films is studied for the first time using the two-temperature model on the basis of the Fokker–Planck formalism. The incident laser radiation is multi-modal, while the electron temperature is described during the first 2 fs. The predictions are intended for use by experimentalists in optoelectronics, photonics, laser processing, electronics, and bio- and nanomedicine. The crucial role of the nano-sized spatial dimensions of the metal sample is highlighted. A significant result of this study is the interdependence between the target’s size, the phonon/lattice characteristics, and the coefficient β (the quotient of non-diffusive phenomena), which varies between zero (pure diffusive case) and one (pure non-diffusive case).

A novel analytical formalism based on the quantum heat transport equation is proposed for the interaction of fs-laser pulses with deoxyribonucleic acid (DNA) strands. The formalism has the intensity of the laser beam and the interaction time between the laser and the DNA as input parameters. To this end, the thermal distribution generated in the irradiated DNA strands was introduced by splitting the laser beam into transverse Hermite-Gauss modes. To achieve this goal, a new powerful mathematical model was developed and applied. Fluctuations in laser intensity were taken into account by modeling them as superpositions of Hermite-Gauss laser modes. These analyses were carried out for a laser pulse duration of 100 fs, where a tiny heat-affected zone is expected, with positive predicted effects on the stability and repeatability of this technology. The main conclusion is that the laser beam spatial distribution intensity plays an essential role in the generation of the shape and magnitude of the thermal field at the junction of the irradiated DNA strands. The model may prove useful in modeling laser beam processing under significant intensity fluctuations. There are at least two main areas of application for the present model of heat transfer from laser to DNA: (i) the study of DNA elongation without destroying the target information (for a sample temperature variation lower than 10 K; in the case of H[1,y]); and (ii) cancer treatment (especially of skin tissue), where we should obtain a temperature variation higher than 10 K (but lower than 30 K; in the case of H[2,y], H[4,y]), in order to eradicate the diseased cells.

In this study, a sol-gel film based on lead sulfide (PbS) quantum dots incorporated into a host network was synthesized as a special nanostructured composite material with potential applications in temperature sensor systems. This work dealt with the optical, structural, and morphological properties of a representative PbS quantum dot (QD)-containing thin film belonging to the Al2O3–SiO2–P2O5 system. The film was prepared using the sol-gel method combined with the spin coating technique, starting from a precursor solution containing a suspension of PbS QDs in toluene with a narrow size distribution and coated on a glass substrate in a multilayer process, followed by annealing of each deposited layer. The size (approximately 10 nm) of the lead sulfide nanocrystallites was validated by XRD and by the quantum confinement effect based on the band gap value and by TEM results. The photoluminescence peak of 1505 nm was very close to that of the precursor PbS QD solution, which demonstrated that the synthesis route of the film preserved the optical emission characteristic of the PbS QDs. The photoluminescence of the lead sulfide QD-containing film in the near infrared domain demonstrates that this material is a promising candidate for future sensing applications in temperature monitoring.

The interest in ultrathin silver (Ag) films has increased due to their high surface plasmon resonance for coatings of only a few nm. Low roughness ultrathin films of 1 to 9 nm have been deposited on different substrates, such as polyethylene terephthalate (PET) and optical glass, using radio frequency (RF) magnetron sputtering. Films show good surface plasmon resonance up to 7 nm thickness, as revealed by the ultraviolet-visible (UV-Vis) spectra. The roughness of the films, investigated by Atomic Force Microscopy (AFM) and Scanning Electron Microscopy (SEM), is small, and one can conclude that depositions are smooth and homogeneous. The bandgap values decrease with film thickness. The refractive index of the films, calculated from ellipsometry measurements, leads to values of under 1 visible domain, with minima in the wavelength range of 400–600 nm. The results are useful for obtaining lower roughness ultrathin Ag films with good surface plasmon resonance for photonic applications.

Purpose This paper aims to develop efficient and simple models for thermal distribution, melt pool dimensions and controlled phase change in the laser additive manufacturing (AM) of bulk and powder particles ceramic materials. Design/methodology/approach This paper proposes new analytical models for the AM of bulk and powder bed ceramic materials. A volumetric moving heat source, along with the complete melting of bulk and powder particle materials, is taken into account. Different values of laser absorption coefficient in solid and liquid states have been used to investigate the phase transformation. Furthermore, the pores and voids dimensions are also included in the modeling. Theoretical predictions have been compared with the experimental analyses and finite element simulations in laser to silicon nitride and laser to alumina interaction. The analysis focuses on the impact of laser power and scanning speed on the melt pool width and depth evolution into the bulk substrate and powder bed. Findings This study shows that the powder particles exhibit a higher thermal distribution value than the bulk substrate because of voids in the powder layer. The laser beam experiences multiple reflections in the presence of porosity/voids, thus increasing the surface absorption coefficient, which becomes relevant with the increment in the pore/void dimension. A direct relationship has been found between the laser power and melt pool dimensions, while the scanning speed displayed an inverse relationship for the melt pool width and length. Larger melt dimensions were inferred in the case of laser–powder particle interaction compared with laser–bulk substrate interaction. A close correlation was found between the analytical simulations, experimental investigations and numerical simulation results within the range of 4%–8%. Originality/value This paper fulfills an identified need to develop efficient and simplified models for ceramics laser AM by taking into account different laser absorption coefficients in solid and liquid form, voids and pores dimensions and controlled phase transformation to avoid vapors and plasma formation. The limitation of the finite element simulation model is that the solution is strongly dependent on the mesh quality and accuracy directly linked to the computation efficiency and time. A finer mesh requires a longer computing time than a coarse mesh. Finite element simulations require, however, specialized skills.

IV-VI semiconductor quantum dots embedded into an inorganic matrix represent nanostructured composite materials with potential application in temperature sensor systems. This study explores the optical, structural, and morphological properties of a novel PbS quantum dots (QDs)-doped inorganic thin film belonging to the Al2O3-SiO2-P2O5 system. The film was synthesized by the sol-gel method, spin coating technique, starting from a precursor solution deposited on a glass substrate in a multilayer process, followed by drying of each deposited layer. Crystalline PbS QDs embedded in the inorganic vitreous host matrix formed a nanocomposite material. Specific investigations such as X-ray diffraction (XRD), optical absorbance in the ultraviolet (UV)-visible (Vis)-near infrared (NIR) domain, NIR luminescence, Raman spectroscopy, scanning electron microscopy–energy dispersive X-ray (SEM-EDX), and atomic force microscopy (AFM) were used to obtain a comprehensive characterization of the deposited film. The dimensions of the PbS nanocrystallite phase were corroborated by XRD, SEM-EDX, and AFM results. The luminescence band from 1400 nm follows the luminescence peak of the precursor solution and that of the dopant solution. The emission of the PbS-doped film in the NIR domain is a premise for potential application in temperature sensing systems.

A novel analytical formalism is proposed based upon Quantum heat transport equation in order to describe the femtoseconds/picoseconds laser pulses interaction with the Deoxyribonucleic acid (DNA). The formalism generates solutions based upon inputs as: voltage, laser beam intensity and laser - DNA interaction time. Thermal waves induced inside irradiated DNA are defined and accounted for. Analytical simulations show that the optimum regime of laser - DNA interaction was reached for a potential carrier generated at the interface equal to 3.5 × 10-3 eV. It has to be mentioned that the formalism breaks down if the potential carrier generated at the interface is inferior to 10-2 eV. Accordingly, for pulse duration inferior to 1 ps, the laser beam spatial-temporal distribution has an essential role in defining the shape and magnitude of the thermal distribution within the irradiated DNA strands.

This chapter deals with the validity/limits of the integral transform technique on finite domains. The integral transform technique based upon eigenvalues and eigenfunctions can serve as an appropriate tool for solving the Fourier heat equation, in the case of both laser and electron beam processing. The crux of the method consists in the fact that the solutions by mentioned technique demonstrate strong convergence after the 10 eigenvalues iterations, only. Nevertheless, the method meets with difficulties to extend to the case of non-Fourier equations. A solution is however possible, but it is bulky with a weak convergence and requires the use of extra-boundary conditions. To surpass this difficulty, a new mix approach is proposed with this chapter resorting to experimental data, in order to support a more appropriate solution. The proposed method opens in our opinion a beneficial prospective for either laser or electron beam processing.

Recently, ultrafast lasers have been developed and potentially become a point of interest worldwide, as their interaction with matter is yet unknown and can be mediated by new physical mechanisms. Real-time experimentation requires enormous costs, and there is therefore a need to develop computational models for this domain. By keeping in view this idea, a non-Fourier heat equation has solved the case of ultrafast laser–material interaction. Initial and boundary conditions were considered, and a one-dimensional mathematical model was presented. The simulations were compared with the experimental results for ultrashort laser–metallic sample interaction, and a close correlation was proven. It was found that the coupling of electron–phonon becomes “zero” due to short laser–material interaction time. The propagation of thermal waves was identified due to non-Fourier heat implementation. When the pulse duration increases, the variation in the thermal distribution becomes trivial due to an inverse correlation between the pulse duration and total energy within the pulse. When the laser–material interaction time decreases from fs to as, the generation of thermal waves increases and the powerful laser intensity acts as a shock wave during laser–material interaction, which causes a higher intensity of the thermal wave.

A semi-analytical-numerical solution is theorized to describe the laser additive manufacturing via laser-bulk ceramic interaction modeling. The Fourier heat equation was used to infer the thermal distribution within the ceramic sample. Appropriate boundary conditions, including convection and radiation, were applied to the bulk sample. It was irradiated with a Gaussian spatial continuous mode fiber laser (λ = 1.075 µm) while a Lambert-Beer law was assumed to describe the laser beam absorption. A close correlation between computational predictions versus experimental results was validated in the case of laser additive manufacturing of silicon nitride bulk ceramics. The thermal field value rises but stays confined within the irradiated zone due to heat propagation with an infinite speed, a characteristic of the Fourier heat equation. An inverse correlation was observed between the laser beam scanning speed and thermal distribution intensity. Whenever the laser scanning speed increases, photons interact with and transfer less energy to the sample, resulting in a lower thermal distribution intensity. This model could prove useful for the description and monitoring of low-intensity laser beam-ceramic processing.

Many of the significant mechanical properties of stainless steel, including ultimate tensile strength, yield strength and hardness, the ductile–brittle transition temperature, and susceptibility to environmental embrittlement, can be improved by grain size refinement. Hall-Petch relation identifies that the improvement can be quantified in a constitutive relation. In this study, a new mathematical model to calculate the number of grains and their average size inside a single printed layer via the laser melting deposition (LMD) process is proposed. The printed layer's thermal history concerning the moving laser beam and co-axial addition of powder debits was analyzed and used to calculate the thermal stress and strain rate. The average grain size within the printed layer was calculated using the Johnson-Mehl-Avrami-Kolmogorov (JMAK) model. The mechanical properties, including ultimate tensile strength, yield strength, and hardness, were estimated using the average grain size. For single depositions of AISI 304 stainless steel powder debits on a steel substrate, dedicated experiments were performed to verify the model’s trustworthiness. Scanning electron microscopy was used to quantify the number and size of grains. Vickers hardness tests were conducted to confirm the mechanical performances predicted by the developed model. It was found that the primary operating parameters strongly influence the grain type, resulting in three varieties of grains: (a) quasi-continuous circular, (b) long lath-shaped, and (c) a combination of the two mentioned above. The deposited layer's thermal history influences the thermal stresses and controls the growing grains' average size. A strong correlation between experimental and computational results, within the range of 10–15 %, and 8–10%, was obtained for the average grain size and Vickers hardness test. The laser scanning speed and laser power were in an inverse relation with the average grain size, while a direct relationship was noticed between the powder feed rate and average grain size. The mechanical computational and experimental results show that the highest yield strength (=208 MPa), ultimate tensile strength (=722 MPa), and hardness (=278 HV) were obtained for the finest grain structure.

Laser cladding processing can be found in many industrial applications. A lot of different materials processing were studied in the last years. To improve the process, one may evaluate the phenomena behaviour from a theoretical and computational point of view. In our model, we consider that the phase transition to the melted pool is treated using an absorption coefficient which can underline liquid formation. In the present study, we propose a semi-analytical model. It supposes that melted pool is in first approximation a “sphere”, and in consequence, the heat equation is solved in spherical coordinates. Using the Laplace transform, we will solve the heat equation without the assumption that “time” parameter should be interpolated linearly. 3D thermal graphics of the Cu substrate are presented. Our model could be applied also for electron cladding of metals. We make as well a comparison of the cladding method using laser or electron beams. We study the process for different input powers and various beam velocities. The results proved to be in good agreement with data from literature.