Advanced manufacturing processes (ME F315)

Department of Mechanical Engineering

BITS Pilani K. K. Birla Goa campus
Instructor in charge: Dr. Biswajit Das
Office No.- E107
Tel: +91-832-2580381 (O)

BITS Pilani K. K. Birla GoaDr.campus

Manoj Kumar Pandey
 LASER = Light Amplification by Stimulated Emission of Radiation

Laser is a device which transforms energy from other forms into (coherent
and highly directional) electromagnetic radiation.

• Electrical energy
• Chemical energy
• Electron beam
• Electric current
• Electromagnetic radiation
•1917 – A. Einstein postulates photons and stimulated emission
•1954 – First microwave laser (MASER), Townes, Shawlow,
Prokhorov
•1960 – First optical laser (Maiman)
•1964 – Nobel Prize in Physics: Townes, Prokhorov, Basov
 Ruby Laser Setup

Theodore (Ted) H. Maiman with

his Invention –
The First Ruby Laser
 “Laser: A Solution looking for a Problem”

Today what can laser do ??

Heat, Cool, Burn,

Excite, Ablate, Cut,
Drill, Trap, Weld
Detect, Cure Separate
Search, Compute, Evaporate,
Measure, Entertain, Communicate,
Fascinating Acts of Lasers
• Measure Distance of Moon from Earth with an Accuracy of
~1cms.

• Create condition of Sun’s surface (Millions K)

• Cools atoms down to a few µK

• Drill 7-8 holes on a single blood cell

• Laser clock: Loose or gain 1s in 15000years

.......
• Can photograph movement of molecules
Blood cell ~5m

• Transmit 1-10 million Video channels simultaneously through

a single cable
• Hold tiny biological molecules as Tweezers

• Laser or Compact Disc can store 2500 times

more information than a Long-disc record

• Detect dreaded disease like cancer, malaria

• Heal burn-wounds

• Cure tuberculosis, cancer

• Detect a single atom

• Detect strain of 1 part in 1021

* What is LASER ?
LASER: Light Amplification by Stimulated Emission of Radiation
* What is Light?
Electromagnetic Radiation :
Carries Energy in the direction of propagation
Wave nature:
Transverse Wave i.e. Oscillation of electric &
magnetic fields are transverse to the direction of propagation.
Velocity in vacuum or air,
c = 3x108m/s,
Frequency =  ,
Wavelength =  = c/ 
In a medium of refractive
index n,
Light velocity, v = c/n
Wavelength = c/ n
Particle nature:
Photon Energy = h,
Photon momentum p = h/c
h= Planck’s constant = 6.626x10-34 J-sec.
What is Stimulated Process?
Light Matter Interaction
Simplest Example : An Atom
Nucleus (protons & neutrons) and electron
shell (electrons)
Bohr model of atom
Electrons can only have certain values of
energy – not all values of energy allowed!
– Electrons can switch between energy
levels by gaining or losing energy
– Electrons can gain energy by absorbing
a little packet of light – photon:
Absorption
– Can lose energy by emitting a photon:
Spontaneous Emission
Photon Energy E = E2 – E1 = h 

Planck constant h = 6.626068 × 10-34 m2 kg / s

Absorption & Spontaneous Emission of Photons

Ordinary Source of Light Emits Light

by Spontaneous Emission Process
Stimulated Emission of Radiation
Stimulated Emission

Photon c Photons
+

Laser Emits Radiation

by Stimulated Process

Probability of Absorption =
Probability of Stimulated emission

In normal condition ( Thermal

Equilibrium) more population in lower
E
energy levels than higher energy
levels,
Absorption dominates over Stimulated
Emission
Stimulated Process to dominate over Absorption
Process: More Population in Excited State
N2

N1> N2 N2> N1

N1
Normal Population Population Inversion

N1> N2 N2> N1

Absorption Amplification
N2> N1

Mirror1 Laser Beam

Laser Mirror2
Light Amplification by Stimulated Emission of Radiation
 Characteristics of Stimulated Emission & Optical Resonator:
* Stimulating & stimulated Photons have same
wavelength, phase, direction, and polarization
* Optical resonator support waves parallel to its axis

 Laser Beam Properties:-

– Coherent Laser Material
Processing
– Monochromatic
– Low Beam Divergence / Directional : Focusibility
– High Brightness
– High Power and High Power Density
– Tunability
– Ultra-short duration pulse
 Ordinary Source of light
Ordinary Source of Light :
Incoherent: No Phase relation between waves
emitted by different atoms
Wide frequency spectrum,  1014Hz
Emits light in all (4 radian) direction

Laser beam : Coherent- Constant phase relation between waves in time and space
Laser emits rays of narrow frequency spectrum,  106-9Hz
Emits light in a small angle ( Divergence angle  a few milli-radian)
Laser Power : mW – Several kW’s
Laser can operate in continuous wave (CW) and pulse mode; Pulse duration ranging
from ms ( 10-3s ) to 10’s of fs (10-15s)
High Power & Low Divergence Exploited in Laser Material Processing
Important components of a laser:
1.Active medium
* Solid: Nd:YAG,
Optical Fiber

* Liquid: Dye Laser

* Gas: He-Ne, CO2,

Excimer Ar+ ion

* Semiconductor
Diodes
2. Excitation or Pump Source to produce population inversion in lasing medium.
* Optical Pump ( Flash Lamp, Other Laser) : Solid State & Fiber Lasers
* Electrical discharge (DC, AC, RF, Pulsed) : Gas Lasers
* Current injection : Diode Lasers
3. Optical Resonator formed by a pair of parallel mirrors, one ~100% reflecting
and other partial reflecting. They provide feedback into the active medium and
facilitates laser beam to build up. Laser beam comes out through the partial
reflecting mirror.
Laser Processing Setup

Laser Processing Setup

* Laser system
* Beam Transport system &
Beam Delivery System
* Workstation

Lasers used in Manufacturing: Lasers those can provide high CW or

average laser power required for material processing

* Solid State Laser : Nd:YAG Laser- Flash Lamp or Diode Laser Pumped
* CO2 Laser
* Diode Laser
* Fiber Laser
* Excimer Lasers
* Ti-Sapphire Laser
 Lasers for Materials Processing Applications & their Characteristics
Characteristics CO2 Laser Nd:YAG Diode Excimer Fiber
Laser Lasers Lasers Laser
Wavelength m 10.6 1.06 0.8-1.0 0.193-0.354 1.06
Laser power,cw Upto 45kW 50W- 2kW Up to --Avg.1kW 10kW
Pulse energy 1-20 J 1-100J 4kW 1-10J,
Efficiency % 10-15 4 Flash lamp pumped 20-40 5 30
–20 Diode pump

Beam Diverg. 1-3 mr. 1 – 25 mr. 1x200 mr 2 – 6 mr. 1-2 mr.

Beam Reflecting Optical Optical Optical Optical
Transportation mirrors fibers fibers fibers fibers
Absorption in Low Moderate Moderate High Moderat
metals ~2-15% ~5-30% ~5-30% 50% e
Life, CW Hrs.) ~ 1000s. ~200 Life of ~ 1000s. 104-107 ~5-30%
Pulsed (Shots) ~106 ~106 lamps (one gas fill)
Size of lasers Large Moderate Compact Moderate Compact
Maintenance 1000-2000 500-1000 5,000- 500-1000 5,000-
intervals (Hr) 10,000 10,000
Mode of CW & CW & CW & Pulsed CW &
operation Pulsed: ms- Pulsed: ms- Modulated 10’s ns Pulsed:
sub-s Sub-ps ms- Sub-
Thank you
for
your patience

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