Micro groove cutting on the surfaces of Cu-B4C nanocomposites by fiber laser

Abstract

Micromachining has evolved into a key facilitating technology and is widely employed today for the creation of complex micro/nano surface features for the parts used in various industries like nano/ micro electro-mechanical systems, medical and telecommunications. At present fiber lasers have made an increasingly significant contribution to micro-fabrications to generate intricate shapes. The increased usage of copper in micro-domains is attributed to the advancements in personal computing and telecom industry. Against this backdrop, this work focuses upon the production of micro-grooves on the surfaces of copper/nano-boron carbide (Cu-B 4 C) metal matrix nanocomposites (MMNCs) by 10 μm fiber laser spot beam. To begin with, Cu-B 4 C MMNCs were synthesized through the powder metallurgical route. Response Surface Methodology-I optimal design was then attempted to optimize the laser machining factors like laser power, number of passes, scanning speed and frequency with the intention to obtain the least surface roughness, minimum kerf width, lower heat affected zone, higher depth and higher material removal. An atomic force microscope is used to inspect the surface characteristics by measuring the roughness values of the surfaces adjacent to the top of micro-grooves. A 3D surface profiler investigated the depth of the groove produced by the fiber laser. Results indicate that a minimum surface roughness of 23.06 nm and a minimum kerf width of 35.49 μm are obtained in the run order 2. Similarly, the groove with a maximum depth of cut of 245.87 μm is achieved in the run order 3. Scanning electron microscopy images helped to examine the surface morphologies and heat-affected zone of the micro-grooved samples.

Systematic review of optimization techniques for laser beam machining

“…In the domain of medicine, LBM makes it possible to produce medical implants and equipment with complicated designs in a precise manner, so assuring that they are biocompatible and do not endanger the patient [19]. The ability of LBM to generate micro-scale features on semiconductor wafers is beneficial to the electronics industry since it enables the fabrication of sophisticated integrated circuits and micro-electromechanical systems (MEMS) [20][21][22][23][24]. In addition, the automobile industry makes use of LBM to produce components that are both robust and lightweight, which improves fuel economy and lowers the negative effect on the environment [25][26][27][28][29].…”

“…A4 Stainless Steel[4], Ceramics[5], Inconel 718[6], Single-Crystalline Diamond[7], Tungsten Carbide[20], Copper[21], Titanium Alloy[22,29], Chemical Vapor Deposition Diamond[23], Copper[24], Polymethyl Methacrylate[25], Gallium Nitride[26], Nickel Alloy[27], Polymethyl Methacrylate[28,89], Alumina Ceramic[106,142], Hydroxyapatite[113], Titanium Alloy (Ti-6Al-4V)[216], Aluminum Alloy (AA 2024)[216], Nickel-Based Super Alloy (Inconel 718)[216], Molybdenum[217], Zirconia (Zro2)[90],…”

Influences of mechanical activation and tartaric acid addition on the efficiency of B4C synthesis

“…Nowadays, there is a growing request for promising carbide ceramics, especially boron carbide (B 4 C) owing to the collection of its unrivaled characteristics like low specific weight, extreme hardness, high melting point, supreme chemical stability, and outstanding Young's modulus [1][2][3]. These mentioned excellent properties have made B 4 C a perfect choice for adaptable usages in the military, cutting and abrasive tools, aerospace, nuclear, and electronic industries [4,5]. Recently, the applications expansion of B 4 C in various industries has caused researchers to develop different methods for the synthesis of this material such as sol-gel [6], magnesiothermic reduction [7,8], carbothermal reduction [9][10][11], microwave synthesis [12], co-reduction in the autoclave [13], and the elemental reaction of boron and carbon [14,15], all of which are designed to achieve a wide range of particle sizes for prepared B 4 C powder.…”

Examining the surface roughness and kerf quality of micro-slots cut on the surfaces of Ti-B4C nanocomposites by WEDM: a desirability approach

“…According to the results of the experiments, the kerf length, power density, server voltage, and wire tension all increase as the pulse on time increases [36,37]. It is noted that researchers trying to generate surfaces with least roughness and low kerf width [38]. Ti tends to weld with the cutting tool due to their strong chemical reactivity, which can result in chipping and early tool failure [39].…”