Abstract: The present invention is generally directed to the materials processing regimes obtained with laser processing using ultra-short laser pulses of subpicosecond (i.e., up to hundreds of femtoseconds) duration, and to the altered materials obtained through such materials processing regimes. Thus various aspects of the present invention are directed to, for example, methods for altering materials by exposure of the materials to one or more pulses of a fs duration laser, while other aspects of the present invention are directed to, for example, materials altered by the methods of the invention. These macro-, micro-, and nanostructured materials have a variety of applications, including, for example, aesthetic applications such as jewelry or ornamentation; biomedical applications, especially medical applications involving biocompatibility bioperformance; catalysis applications; and modification of, for example, the optical and hydrophilic properties of materials.

Abstract: A method is disclosed for rounding and/or flattening an annular part that is out of round and/or not flat due to non-uniform internal stresses. The part is first checked for out of round and/or out of flat conditions. Out of round parts are then rounded by introducing compressive stresses into selected surface sections of the part whereby the introduced compressive stresses cause deformation of the annular part thereby rounding the annular part. Alternatively, out of round parts are rounded by relieving compressive stresses in selected surface sections of the part whereby the relieving of compressive stresses causes deformation of the annular part thereby rounding the annular part. Out of flat parts are flattened by introducing compressive stresses into selected surface sections of the part whereby the introduced compressive stresses cause deformation of the annular part thereby flattening the annular part.

Abstract: A method for laser shock peening an article, such as a gas turbine engine airfoil, with varying thickness by varying a surface fluence of a laser beam over a laser shock peening surface as a function of the thickness beneath a laser shock peened spot formed by the beam on the surface. The fluence may be equal to the thickness multiplied by a volumetric fluence factor, the volumetric fluence factor being held constant over the laser shock peening surface. The volumetric fluence factor may be in a range of about 1200 J/cm3 to 1800 J/cm3 and more particularly about 1500 J/cm3. The method may include varying energy in the laser beam using a computer program controlling firing of the laser beam. A device such as an optical attenuator external to a laser performing firing may be used to vary the energy.

Abstract: A process for electromagnetic (EM) energy-induced solid to liquid phase transitions in metals is disclosed. The method utilizes coherent EM fields to transform solid materials such as silicon and aluminum without significant detectable heat generation. The transformed material reverts to a solid form after the EM field is removed within a period of time dependent on the material and the irradiation conditions.

Abstract: Methods and apparatus are provided for igniting, modulating, and sustaining a plasma for at least partially decrystallizing a surface of an object. In one embodiment, a method is provided for decrystallizing a surface of an object by forming a plasma (such as by subjecting a gas to an amount of electromagnetic radiation, optionally in the presence of a plasma catalyst) and exposing the surface of the object to the plasma.

Abstract: A method for heat-treating a plurality of microelectronic structures attached to a non-metallic substrate is disclosed. The method comprises the steps of: (a) placing the non-metallic substrate and the plurality of microelectronic structures in an oscillating electromagnetic field, whereby the plurality of microelectronic structures are heated by the oscillating electromagnetic field and the non-metallic substrate is essentially not heated by the oscillating electromagnetic field; (b) maintaining the non-metallic substrate and the plurality of microelectronic structures in the oscillating electromagnetic field until each of the plurality of microelectronic structures obtains a defined heat-treatment temperature substantially greater than an ambient temperature; (c) removing the non-metallic substrate and the plurality of microelectronic structures from the oscillating electromagnetic field; and (d) cooling the plurality of microelectronic structures to the ambient temperature.

Abstract: A process and a device for the pulsed plasma strengthening of a metallic component, in which the surface to be strengthened is not acted on in a merely punctiform manner and the roughness of the surfaces is not adversely effected, comprising the steps of: providing a metallic component (1, 8, 18), coating a surface section (7, 7?) of the metallic component (1, 8, 18) with a sublimable material (22), applying a pulsed plasma jet (20) to the surface section (7, 7?) in such a way that the material is sublimed and as a result a shock wave is introduced into the component (1, 8, 18) in order to form residual compressive stresses in a region which extends from the surface section (7, 7?) into the component (1, 8, 18).

Abstract: Selective laser and induction hardening are applied to areas of a water jacketed engine cylinder liner to provide improved resistance to scuffing resulting from the rubbing contact of the walls and piston rings of an associated piston. An upper bore portion and port relief areas of the liner are fully induction hardened to improve wear resistance. The port area is then fully laser hardened to improve wear resistance. If desired, the laser hardening process may continue beyond the intake port area to the port relief areas to ensure full hardening of the port relief areas and continuous hardening between the intake ports and the port relief areas to improve wear resistance.

Abstract: A method for laser shock peening an article including laser shock peening a first area with at least one high fluence laser beam and laser shock peening a border area between the first area and a non-laser shock peened area of the article with at least one first low fluence laser beam. The border area may be laser shock peened with a second low fluence laser beam or more low fluence laser beams wherein the second low fluence laser beam and others have a lower fluence than the first low fluence laser beam. The border area may be laser shock peened with progressively lower fluence laser beams starting with the one first fluence laser beam wherein the progressively lower fluence laser beams are in order of greatest fluence to least fluence in a direction outwardly from the first area through the border area to the non-laser shock peened area.

Abstract: A method for refining the grain size of alloys which undergo ferromagnetic to paramagnetic phase transformation and an alloy produced therefrom. By subjecting the alloy to a timed application of a strong magnetic field, the temperature of phase boundaries can be shifted enabling phase transformations at lower temperatures.

Abstract: A method for laser annealing a part includes the steps of providing automated tooling, providing a laser, and providing a metal part to be annealed. The method also includes the steps of moving either one of the laser or metal part by the automated tooling relative to a stationary one of the other laser or metal part. The method further includes the steps of supplying power to the laser to heat a portion of the metal part to a predetermined temperature to anneal the portion of the metal part as the laser and metal part move relative to each other.

Abstract: A method of depositing a hard wear resistant surface onto a porous or non-porous base material of a medical implant. The medical implant device formed by a Laser Based Metal Deposition (LBMD) method. The porous material of the base promotes bone ingrowth allowing the implant to fuse strongly with the bone of a host patient. The hard wear resistant surface provides device longevity when applied to bearing surfaces such as artificial joint bearing surface or a dental implant bearing surface.

Abstract: A method of heat treating tool steel by using a high intensity infrared heating source, said source being tungsten halogen heat lamps which operate in air, non-air and/or vacuum environments, and a tool steel heat treat system which includes a furnace containing said tungsten halogen lamp means, a lining of a reflective metal and, preferably, support structure for the tool steel workpieces which are composed of ceramic or other high melting point material.

Abstract: A method of manufacturing a workpiece involves performing any one of various post-processing part modification steps on a workpiece that has been previously subjected to laser shock processing. In one step, material is removed from the compressive residual stress region of the processed workpiece. Alternately, the workpiece may be provided with oversized dimensions such that the removal process removes an amount of material sufficient to generate a processed workpiece having dimensions substantially conforming to design specifications. Alternately, the material removal process is adapted to establish a penetration depth for material removal that coincides with the depth at which the workpiece exhibits maximum compressive residual stress. Alternately, a first high-intensity laser shock processing treatment is performed on the workpiece, followed by the removal of material from the compressive residual stress region, and then a second low-intensity laser shock processing treatment is performed on the workpiece.

Abstract: Process for the effective production of very wear-resistant layers in the thickness range of 0.2 to approx. 3 mm by way of inductively supported surface layer modification. It can be used particularly advantageously for the protection of components of hardenable steels and cast iron with abrasive, corrosive, high-temperature corrosive or mineral sliding wear loading. With the process according to the invention a local two-stage inductive short-time preheating takes place directly before the surface layer coating. Due to the invention it is possible to coat even hardenable steels or other materials difficult to coat without cracking. Furthermore, even harder coating materials susceptible to cracking which provide better wear-resistances can be used. In addition, process speeds and surface coating performances can be achieved that are higher by a factor of 10 compared with conventional laser build-up welding.

Abstract: The invention relates to semifinished and finished products made from special corrosion-resistant precipitation-hardened austenitic steel containing a large amount of intersticially dissolved nitrogen, comprising substantially smooth surfaces. The invention also relates to a method for producing corresponding semifinished and finished items. The aim of the invention is to produce semifinished and finished item and to provide an economical method for the production thereof, combining both solidity and resistance to corrosion. This is achieved by precipitation-hardening areas of the steel material.

Abstract: The properties of a metal piece are altered by laser peening the piece on the first side using an acoustic coupling material operatively connected to the second side and subsequently laser peening the piece on the second side using an acoustic coupling material operatively connected to the first side.

Abstract: A method using of a magnetic field to affect residual stress relief or phase transformations in a metallic material is disclosed. In a first aspect of the method, residual stress relief of a material is achieved at ambient temperatures by placing the material in a magnetic field. In a second aspect of the method, retained austenite stabilization is reversed in a ferrous alloy by applying a magnetic field to the alloy at ambient temperatures.

Abstract: The adhesion of a capping layer, e.g., silicon nitride, to inlaid Cu is improved with an attendant reduction in hillock formation and, hence, improvement in electromigration resistance, by laser thermal annealing the exposed surface of the inlaid Cu after CMP to remove copper oxide therefrom. Embodiments include laser thermal annealing in NH3 or H2 at a temperature of about 370° to about 420° for a short period of time, e.g., about 10 to about 100 nanoseconds, to remove the copper oxide. Embodiments also include sequentially and contiguously laser thermal annealing the exposed planarized surface of inlaid Cu, ramping up the introduction of SiH4 and then initiating (PECVD) of a silicon nitride capping layer. Embodiments also include Cu dual damascene structures formed in dielectric material having a dielectric constant (k) less than about 3.9.

Abstract: A process and a device for the pulsed plasma strengthening of a metallic component, in which the surface to be strengthened is not acted on in a merely punctiform manner and the roughness of the surfaces is not adversely effected, comprising the steps of: providing a metallic component (1, 8, 18), coating a surface section (7, 7′) of the metallic component (1, 8, 18) with a sublimable material (22), applying a pulsed plasma jet (20) to the surface section (7, 7′) in such a way that the material is sublimed and as a result a shock wave is introduced into the component (1, 8, 18) in order to form residual compressive stresses in a region which extends from the surface section (7, 7′) into the component (1, 8, 18).

Abstract: A material, such as track member for a linear motion guide, having a plurality of rows of portions to be hardened which are thermally influenced on each other, is hardened by emitting laser beams so as to simultaneously irradiate a plurality of rows of portions of the material to be hardened, and moving the laser beams irradiating the rows of portions to be hardened relatively in a longitudinal direction of the portions to be hardened. In this hardening process, the laser beam irradiation is performed such that, in a sectional plane perpendicular to an optical axis of the laser beam, a length of a laser beam irradiation shape in the longitudinal direction of the portion to be hardened is set to be longer than a length thereof in a direction perpendicular to the longitudinal direction.

Abstract: The invention concerns a method whereby at least a predefined zone (A) of the object (2) is irradiated with a laser beam (4) capable of heating said zone sufficiently, to a temperature less than the material melting point, to provoke a change in the microstructure (for example crystallisation or recrystallisation) of said zone, said zone being heated at a temperature and for a time interval not rendering the material amorphous. The invention is applicable for example to reversible actuators and grippers.

Abstract: Titanium-aluminum alloy is prepared as a master alloy, and the aluminum master alloy and a pure titanium material are melted by an electron beam to yield titanium alloy.

Abstract: The present invention relates to the production of ultrafine powders using a microwave plasma apparatus and chemical synthesis technique. Microwaves generated by a magnetron (1) are passed through waveguides (2) before they arrive at the head of a plasmatron (3). These high energy microwaves ionize a plasma gas, thus releasing large amounts of energy. The energy thus released is utilized to initiate and sustain chemical reactions between the desired elements being pumped in a spiral pattern into the plasmatron (3). The reaction products are quenched rapidly in a reactor column (4) into ultrafine powders.

Abstract: A method for hardening the grooves of steel pistons of steel piston heads whereby hardening of the bottom of the grooves is avoided. The laser beam is directed onto the sides of the groove in an approximately tangential direction in relation to the outer diameter of the piston.

Abstract: The invention relates to a process for the effective production of very wear-resistant layers in the thickness range of 0.2 to approx. 3 mm by means of inductively supported surface layer finishing. It can be used particularly advantageously for the protection of components of hardenable steels and cast iron with abrasive, corrosive, high-temperature corrosive or mineral sliding wear strain.

Abstract: A method for producing a stainless steel with improved corrosion resistance includes homogenizing at least a portion of an article of a stainless steel including chromium, nickel, and molybdenum and having a PREN of at least 50, as calculated by the equation: PREN=Cr+(3.3×Mo)+(30×N), where Cr is weight percent chromium, Mo is weight percent molybdenum, and N is weight percent nitrogen in the steel. In one form of the method, at least a portion of the article is remelted to homogenize the portion. In another form of the method, the article is annealed under conditions sufficient to homogenize at least a surface region of the article. The method of the invention enhances corrosion resistance of the stainless steel as reflected by the steel's critical crevice corrosion temperature.

Abstract: A method of laser shock peening a metallic part by firing a laser on a coated laser shock peening surface of the part which has been covered with an explosive coating containing at least one explosive ingredient. Two or more explosive ingredients having different shock sensitivities may be used and the laser beam is fired with sufficient power to explode at least some amount of each of the explosive ingredients.

Abstract: A uniquely surface-modified metallic part is provided by the utilization of microwave energy to promote diffusion of desired metals into the surface of the formed metallic part.

Abstract: The invention generally provides an apparatus and a method of removing metal oxides, particularly copper oxides and aluminum oxides, from a substrate surface. Primarily, the invention eliminates sputtering of copper oxide from the bottom of an interconnect feature onto the side walls of an interconnect feature, thereby preventing diffusion of the copper atom through the dielectric material and degradation of the device. The invention also eliminates sputtering of the copper oxides onto the chamber side walls that may eventually flake off and cause defects on the substrate. The method of reducing metal oxides from a substrate surface comprises placing the substrate within a plasma processing chamber, flowing a processing gas comprising hydrogen into the chamber, and maintaining a plasma of the processing gas within the chamber through inductive coupling.

Abstract: An alloy comprising tantalum and silicon is described. The tantalum is the predominant metal present. The alloy also has a uniformity of tensile strength when formed into a wire, such that the maximum population standard deviation of tensile strength for the wire is about 3 KSI for an unannealed wire at finish diameter and about 2 KSI for an annealed wire at finish diameter. Also described is a process of making a Ta—Si alloy which includes reducing a silicon-containing solid and a tantalum-containing solid into a liquid state and mixing the liquids to form a liquid blend and forming a solid alloy from the liquid blend. Another process of making a Ta—Si alloy is described which involves blending powders containing tantalum or an oxide thereof with powders containing silicon or a silicon-containing compound to form a blend and then reducing the blend to a liquid state and forming a solid alloy from the liquid state.

Abstract: A tin layer and a nickel layer are stacked sequentially on a given substrate to form a multilayered film composed of the tin layer and the nickel layer. Then, laser beams are irradiated onto the multilayered film to form a tin-nickel alloy film, having stable phases composed of equilibrium phases such as Ni3Sn phase through the diffusion of the tin elements of the tin layer into the nickel layer.

Abstract: The present invention relates to a method of baking treatment of steel product parts using a high frequency or ultra-high frequency for preventing delayed fracture from occurring due to diffusive hydrogen occluded in steel parts, for example, screws, bolts and the like, or for heating surface layers of the steel parts to generate a difference in temperature between the surface layers and interiors of the steel parts, thereby causing distortion in lattices, wherein the surface layers of the steel parts are rapidly heated to 100 to 300° C. with a high frequency or ultra-high frequency at 10 KHz or higher to remove the diffusive hydrogen which is involved in hydrogen embrittlement, or to transfer an existing state to non-diffusive hydrogen which is not involved in the hydrogen embrittlement.

Abstract: Disclosed are reinforced metal matrix composites and methods of shaping powder materials to form such composites. Articles of manufacture are formed in layers by a laser fabrication process. In the process, powder is melted and cooled to form successive layers of a discontinuously reinforced metal matrix. The matrix exhibits fine grain structure with enhanced properties over the unreinforced metal, including higher tensile modulus, higher strength, and greater hardness. In some preferred embodiments, an in-situ alloy powder, a powder metallurgy blend, or independently provided powders are reinforced with boron and/or carbon to form the composite.

Abstract: A method for producing a stainless steel with improved corrosion resistance includes homogenizing at least a portion of an article of a stainless steel including chromium, nickel, and molybdenum and having a PREN of at least 50, as calculated by the equation:

Abstract: A laser repair method for a high gamma prime content Ni base superalloy substrate surface, with gamma prime content in the range of at least about 30 volume %, conducts the repair at ambient temperature without preheating the substrate surface and by controlling processing parameters to avoid cracking of the resulting weld bead during and after welding. The laser beam, operating in a power range of about 50-10000 watts per centimeter, is focused away from the substrate surface to provide a laser spot in the size range of about 0.03-0.2″. A relative movement between the substrate surface and the laser beam, for example at a rate in the range of about 1-100 inches per minute, provides an interaction time of no greater than about 10 seconds between the laser beam and the substrate surface. Concurrently, a repair alloy powder is deposited in the laser beam to melt and fuse the repair alloy powder into a molten repair alloy deposited on the substrate surface.

Abstract: A flat plate member with gear portion is formed to a predetermined shape by pressing a flat steel raw material having a composition comprising, by weight, 0.10-0.18% C, less than 0.03% Si, 0.60-1.50% Mn, less than 0.020% P, less than 0.013% S, 0.001-0.004% B and the balance Fe with inevitable impurities, wherein quenching is performed on only the gear portion.

Abstract: A method for treating a surface of a brake rotor to enhance the brake rotor's durability is disclosed. The method includes, positioning the brake rotor adjacent a laser light source, wherein the laser light source produces a laser beam, projecting the laser beam onto a surface of the brake rotor, directing a processing gas toward the surface of the rotor adjacent the laser beam, rotating the rotor at a predefined rotational speed, and repeating the above steps until an entire surface of the rotor is treated with the laser beam.

Abstract: A method and apparatus are provided for treating the surface of a metal body through phase transformation, ion implantation, and/or diffusion and to form new phases of metallic materials. The method and apparatus have been shown to be particularly useful to improve the hardness and corrosion resistance of ferrous and non-ferrous metals. Generally, the method comprises irradiating a portion of the metal body (18) with a laser (12), and directing a stream of gas (22) onto the same portion of the metal body simultaneously with and preferably for a duration after the laser is turned off. Preferably, the laser (12) is a carbon dioxide laser operated in a pulsed mode to control heating of the metal (18). The gas (22) is preferably carbon dioxide to quickly cool the metal when the laser is off, and to provide carbon atoms for deposition onto the body.

Abstract: The present invention relates to the production of ultrafine powders using a microwave plasma apparatus and chemical synthesis technique. Microwaves generated by a magnetron (1) are passed through waveguides (2) before they arrive at the head of a plasmatron (3). These high energy microwaves ionize a plasma gas, thus releasing large amounts of energy. The energy thus released is utilized to initiate and sustain chemical reactions between the desired elements being pumped in a spiral pattern into the plasmatron (3). The reaction products are quenched rapidly in a reactor column (4) into ultrafine powders.

Abstract: This invention relates to a method of using a laser to produce a decorative appearance on the surface of a bumper. More specifically, the present invention relates to a laser alloying method to create a decorative alloyed layer on the surface of a bumper.

Abstract: A uniquely surface-modified metallic part is provided by the utilization of microwave energy to promote diffusion of desired metals into the surface of the formed metallic part.

Abstract: The present invention relates to the production of ultrafine powders using a microwave plasma apparatus and chemical synthesis technique. Microwaves generated by a magnetron (1) are passed through waveguides (2) before they arrive at the head of a plasmatron (3). These high energy microwaves ionize a plasma gas, thus releasing large amounts of energy. The energy thus released is utilized to initiate and sustain chemical reactions between the desired elements being pumped in a spiral pattern into the plasmatron (3). The reaction products are quenched rapidly in a reactor column (4) into ultrafine powders.

Abstract: The invention relates to a process for producing wear-resistant edge layers on precipitation-hardenable materials, in particular precipitation-hardenable or martensite-hardened steels.

Abstract: The invention concerns a wear-resistant camshaft and a method of producing the same. Objects in which the application of the invention is possible and useful are all cast-iron parts which are subject to wear as a result of lubricated friction. The wear-resistant camshaft consists of cast-iron and it has a surface layer consisting of a ledeburitic remelted layer with a high cementite portion, and, lying thereunder, a martensitic hardening zone, whereby according to the invention. a. the remelted layer consists of finely dispersed ledeburitic cementite with thicknesses of ≦1 &mgr;m and a metallic matrix of a phase mixture of martensite and/or bainite, residual austenite, as well as less than 20% finely laminated pearlite with a distance of ≦0.1 &mgr;m between the lamelias, and b. the hardening layer is formed from a phase mixture of martensite and/or bainite, partially dissolved pearlite, and residual austenite.

Abstract: A method and apparatus for tempering the shank portion only of die blocks which comprises subjecting the shank portion of a die block or other large metal part to electrical energy derived from induction heating or infrared heating to a controlled depth, preferably just sufficiently deep to temper the shank portion but not sufficiently deep to temper the hardened working portion of the part.

Abstract: In a steel member surface treatment method, only a surface layer portion of the steel member is heated to its melting point or higher to form a melt, by high density energy-beam irradiation. Subsequently, the melted portion is rapidly cooled to a martensitic transformation region, to form a martensitic structure. The temperature increasing rate in irradiation of the surface layer of the steel member is preferably 7500° C./second or greater. Thereby, thermal strain and quenching failure are reduced even if the steel member is a thin plate component and a high production efficiency can be achieved.

Abstract: A device (100) for the thermal treatment of friction lining surfaces (19) (scorching) is characterized in that at least one infrared light source is placed in the heating station (10) for heating the friction lining surfaces. Short-wave infrared light of approximately 780 to 1400 nm with a maximum at 1200 nm is preferably used. A suction bell (11) and a fan (12) for removing the decomposition gas are above the heating station (10). The irradiation can take place in depression or in special chemical atmospheres. An infrared thermometer (20) supervises the temperature of the friction lining surfaces (19) and eventually causes an elimination (14) of parts. A cooling station (17) is following the heating station (10).

Abstract: Embodiments include a process including providing a microwave radiation source and a processing chamber. The process includes generating a region of pure magnetic field from the microwave radiation in the processing chamber. A region of pure electric field from the microwave radiation is also generated. A material is positioned in the region of pure magnetic field while no portion of the material is positioned in the region of pure electric field, and the material is heated in the region of pure magnetic field. The heating may be conducted to sinter the material. The material may includes a metal.

Abstract: The invention concerns a method for making a composite metal product by adding at least one substance to said product, which consists in using a metal product in the form of a continuous strip (1) moved in a vacuum chamber (2), applying the substance on said strip and diffusing said substance at least partially into the strip when it is passing in the vacuum chamber maintaining it at a temperature lower than its melting point, but sufficiently high for enabling said diffusion.