Abstract: A system and method for monitoring real time stress development of laser additive manufacturing. In some embodiments, the system comprises a laser machine, a laser deposition head, an illumination laser, a line laser, two CCD cameras, a spectrum meter, a computer, and an ultrasonic shot head. The CCD camera can record the molten pool height and the line laser can be directed behind the molten pool to measure the shape and/or height of the newly formed layer. The computer builds a real-time FEM model of the layer, calculates the displacement of the solidified surface, and then calculates the stress formed in the layer. The spectrum meter monitors for non-stress induced defects. The data is transferred into a computer to determine whether defects will occur and control the laser deposition and ultrasonic shot head to treat the area and prevent emergence of stress induced defect.

Abstract: Apparatus and methods provide discreet and inexpensive screening for pathogens including Covid-19. A sample of bodily fluid such as saliva is energized to generate a plasma, and the optical emission spectra from the plasma is collected and analyzed used a smart optical monitoring system (SOMS) to determine the presence or increase of a protein indicative of a pathogen. The plasma may be generated with a spark, and light may be collected with a smartphone for remote analysis. In particular, in patients with Covid-19 serum concentrations of acute phase proteins (APPs), such as C-reactive protein (CRP) and ferritin, are increased in the cases that develop more severe disease. In addition, increases in serum of several interleukins (IL), such as IL-6 and IL-10, have been described in Covid-19 patients, and these cytokines are known to be mediators of the APPs response.

Abstract: A smart additive manufacturing system uses a spectrometer to collect emission spectra along an optical axis from a laser-generated plasma plume, and wherein the laser beam and the optical axis of the emission spectra are co-axial, at least in the vicinity of the melt pool, thereby minimizing the fluctuation of spectral signals caused by ambient pressure/gas variations. The laser beam passes through a beam splitter prior to reaching the work piece, and the emission spectra from the work piece are redirected by the beam splitter to the spectrometer, and wherein the laser beam and the optical axis of the emission spectra are co-axial between the work piece and the beam splitter. The beam splitter may be a dichroic mirror or other type of beam splitter, including holographic beam splitters, and spectral filtering may be carried out with separate optical elements, as long as the overall goal of on-axis excitation and collection is achieved.

Abstract: A method and apparatus for direct writing of single crystal super alloys and metals. The method including heating a substrate to a predetermined temperature below its melting point; using a laser to form a melt pool on a surface of the substrate, wherein the substrate is positioned on a base plate, and wherein the laser and the base plate are movable relative to each other, the laser being used for direct metal deposition; introducing a superalloy powder to the melt pool; and controlling the temperature of the melt pool to maintain a predetermined thermal gradient on a solid and liquid interface of the melt pool so as to form a single crystal deposit on the substrate. The apparatus configured to generally achieve the aforementioned method.

Abstract: A microstructure detector and in-situ method for real-time determination of the microstructure of a material undergoing alloying or other phase transformation. The method carried out by the detector includes the steps of: (a) detecting light emitted from a plasma plume created during phase transformation of a material; (b) determining at least some of the spectral content of the detected light; and (c) determining an expected microstructure of the transformed material from the determined spectral content. Closed loop control of the phase transformation process can be carried out using feedback from the detector to achieve a desired microstructure.

Abstract: A microstructure detector and in-situ method for real-time determination of the microstructure of a material undergoing alloying or other phase transformation. The method carried out by the detector includes the steps of: (a) detecting light emitted from a plasma plume created during phase transformation of a material; (b) determining at least some of the spectral content of the detected light; and (c) determining an expected microstructure of the transformed material from the determined spectral content. Closed loop control of the phase transformation process can be carried out using feedback from the detector to achieve a desired microstructure.

Abstract: A method and apparatus for direct writing of single crystal super alloys and metals. The method including heating a substrate to a predetermined temperature below its melting point; using a laser to form a melt pool on a surface of the substrate, wherein the substrate is positioned on a base plate, and wherein the laser and the base plate are movable relative to each other, the laser being used for direct metal deposition; introducing a superalloy powder to the melt pool; and controlling the temperature of the melt pool to maintain a predetermined thermal gradient on a solid and liquid interface of the melt pool so as to form a single crystal deposit on the substrate. The apparatus configured to generally achieve the aforementioned method.

Abstract: A microstructure detector and in-situ method for real-time determination of the microstructure of a material undergoing alloying or other phase transformation. The method carried out by the detector includes the steps of: (a) detecting light emitted from a plasma plume created during phase transformation of a material; (b) determining at least some of the spectral content of the detected light; and (c) determining an expected microstructure of the transformed material from the determined spectral content. Closed loop control of the phase transformation process can be carried out using feedback from the detector to achieve a desired microstructure.

Abstract: An ultra-short pulse laser physically and/or chemically modifies a substrate surface. A laser ablation process is configured to form raised surface features on the substrate. The laser also functions as the energy source in a chemical vapor deposition (CVD) process. The laser delivers energy to the substrate with parameters such as pulse energy, size, duration, and spacing sufficient to simultaneously vaporize substrate material and cause the substrate material to react with a controlled environment that includes constituents of a desired coating composition. A battery electrode having a face with microneedle features coated with an active metal compound can be produced by the process. The active metal compound is a lithium-containing compound in a lithium-ion battery.

Abstract: Apparatus and methods for direct writing of single crystal super alloys and metals are provided. In one method, a substrate is heated to a pretermined temperature below its melting point, and a laser is used to form a melt pool on a surface of a substrate. The substrate is positioned on a base plate, and the laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition and the substrate is heated to a temperature below its melting point. A superalloy powder is introduced to the melt pool, and the temperature of the melt pool is controlled to maintain a predetermined thermal gradient on a solid and liquid interface of the melt pool so as to form a single crystal deposit on the substrate.

Abstract: An ultra-short pulse laser physically and/or chemically modifies a substrate surface. A laser ablation process is configured to form raised surface features on the substrate. The laser also functions as the energy source in a chemical vapor deposition (CVD) process. The laser delivers energy to the substrate with parameters such as pulse energy, size, duration, and spacing sufficient to simultaneously vaporize substrate material and cause the substrate material to react with a controlled environment that includes constituents of a desired coating composition. A battery electrode having a face with microneedle features coated with an active metal compound can be produced by the process. The active metal compound is a lithium-containing compound in a lithium-ion battery.

Abstract: A microstructure detector and in-situ method for real-time determination of the microstructure of a material undergoing alloying or other phase transformation. The method carried out by the detector includes the steps of: (a) detecting light emitted from a plasma plume created during phase transformation of a material; (b) determining at least some of the spectral content of the detected light; and (c) determining an expected microstructure of the transformed material from the determined spectral content. Closed loop control of the phase transformation process can be carried out using feedback from the detector to achieve a desired microstructure.

Abstract: A method for laser welding a pair of overlapping metal members together and a weld joint produced by the method. At least one of the metal members has a protective metal coating. The method includes applying a thin layer of an alloying agent on at least one of the metal members between the metal members, melting the protective metal coating and the alloying agent to form an alloy that is disposed between the overlapping members with zero gap, welding the overlapping metal members together to form a weld, and controlling the amount of the alloying agent such that the extended solid solubility of the alloying agent in the weld is not exceeded.

Abstract: A method for laser welding a pair of overlapping metal members together and a weld joint produced by the method. At least one of the metal members has a protective metal coating. The method includes applying a thin layer of an alloying agent on at least one of the metal members between the metal members, melting the protective metal coating and the alloying agent to form an alloy that is disposed between the overlapping members with zero gap, welding the overlapping metal members together to form a weld, and controlling the amount of the alloying agent such that the extended solid solubility of the alloying agent in the weld is not exceeded.

Abstract: Light at known angles is impinged onto an object whose contour is to be mured and a camera is used to receive the reflected light which is then recorded. A computer processes the images, mathematically manipulating them so that surface slopes are known. The slopes are than integrated to obtain local elevations which represent the object contour.