National Science Foundation Industry/University
Cooperative Research Center for Laser and
Plasma for Advanced Manufacturing
Mool C. Gupta
Langley Distinguished Professor
Department of Electrical & Comp. Engr.
University of Virginia
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
I/UCRC Mission and Vision
Mission:
• To contribute to the nation’s research
infrastructure base by developing long-term
partnerships among industry, academe and
government
• To leverage NSF funds with industry to support
graduate students performing industrially relevant
research
Vision:
• To expand the innovation capacity of our
nation’s competitive workforce through
partnerships between industries and universities
Source: Dr. Babu DasGupta, NSF
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
What Does an I/UCRC Offer
Industry
Networking
IP
Pre-Publication
Technical Papers
Innovation
New
Products &
Processes
Industry driven R&D
projects that are mutually
beneficial
Access to
Students
Primarily funded by industry members, with
NSF taking a supporting role
Babu DasGupta (NSF)
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
I/UCRC Benefits
Industry
University
• Allows industries to interact with pre• Stable funding source
competitive research
for research
• An avenue to investigate a topic
which may otherwise not be done
• Exposes the academic
community to industrial
• Allows industries to utilize the
problems
resources of a university
• An excellent recruiting tool for
building the future of the company
• Establishes a meaningful
research focus –
• Royalty-free non-exclusive rights to IP industrially relevant
• Minimal overhead on membership
funds (more effective than contracts) • Provides support for
research and students
• Increased interaction capabilities
(networking) among various
members.
Win - Win
Babu DasGupta (NSF)
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
I/UCRC Center Sites
Babu DasGupta (NSF)
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
National Science Foundation Industry/University
Cooperative Research Center For Laser Based
Manufacturing
Center Mission
Develop Science, Engineering
and Technology Base for
Laser and Plasma Processing
of Materials, Devices and
Systems for Advanced
Manufacturing
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Center Partnership Concept
Partnership
Industry
Fed. Labs
State
Me
Membership
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Projects
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
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NSF
UNIVERSITY OF VIRGINIA
Multi-University Center
• University of Virginia
• University of Michigan-Ann Arbor
• Southern Methodist University
• University of Illinois-UrbanaChampaign
University of Texas at Dallas, North Carolina State
University & Drexel University are applying for joining the
center
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Industrial Advisory Board Members
AREVA Group
NAVAIR
GE Global Research
General Motors R&D
Lockheed Martin
Halliburton
IMRA
Nuvonyx
Trinity Industries
Army Research Office
TRUMPF
Begneaud Mfr.
Lee Laser, Inc.
Fruth Innovative Technologies, GmbH, Germany
NASA Langley Research Center
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Center Historical Prospective
Jan. 2002
May 2002
Nov. 2004
April 2005
May 2009
NSF-supported planning workshop
Startup for NSF I/UCRC
University of Michigan joins LAM
Southern Methodist University joins LAM
University of Illinois joins LAM
•Center membership: $35k per year
•Board Members have access to center research of over $1M with
an investment of $35k in membership.
•Contact: Dr. Mool C. Gupta, Langley Distinguished Professor &
Director for NSF I/UCRC Laser Center, University of Virginia, Dept. of
Elect. & Comp. Engr.; Thornton Hall, 351 McCormick Rd,
Charlottesville, Virginia 22904-4743; E-mail: mgupta@virginia.edu,
Phone: 434-924-6167; Fax: 434-924-8818, center website:
http://www.seas.virginia.edu/lam
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Summary of Center Projects
Laser Welding:
- Laser welding of light materials- GM
-Rapid manuf. by e-beam welding-ARL
-Gas tungsten arc welding- Lockheed Martin
-Galvanized steel welding-Toyota
Laser Micromachining: -Laser micromachining of Al alloys-NASA
-Laser micromachining for fluidics-IMRA
- Laser drilling of Ni superalloys-GE
Laser Cladding:
-Laser sintering of inconel 690-AREVA
- Laser Cladding for erosion-Halliburton
Laser Diagnostics-
Laser corrosion detection-Navair
-Composition diagnostics during DMD- GE
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
• High Power Plasma Applications
• Atmospheric Plasma Applications
• Optical sensors
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Center Membership Benefits
• Access to over 1 million dollar research
carried out by seven universities
• Industry project
• Minimum Overhead ( Univ. contributes)
• Recruitment of students
• Networking and new ideas
• Royalty free non exclusive IP rights
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Center Website
http://www.seas.virginia.edu/lam
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
NSF I-CORPS
• Very competitive, proposals all over the
country
• Received award on “Laser Microtexturing
Applications”
• Last week attended a course on
entrepreneurship at Stanford University by
all three team members
• 5 week webx class, significant commitment
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Participants
Principal Investigator:
Prof. Mool C. Gupta
Graduate Students:
Christian Rothenbach
Tyson Baldridge
Ankit Shah
Undergraduate students: Chris Cunningham,
Kyle Smalkowski
Christian Speck
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Research Projects
Research Topic
1. Laser removal of nuclear
contamination and corrosion
with process monitoring
Sponsor
AREVA
2 Optical Corrosion Sensor
NAVAIR
3. Laser texturing for solar thermal NASA
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Additional Projects
Research topics
Sponsor
1. Ultrafast laser micro-texturing of surfaces
NASA
2. Laser and plasma sintering of thermoelectrics
NASA
3. Metamaterials for infrared applications
NASA
4. High temperature measurements by fiber optic NASA
fluorescence method
5. Textured surfaces for photovoltaics
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
NASA
UNIVERSITY OF VIRGINIA
Publications-Univ. of Virginia
B. K. Nayak, K. Sun, C. Rothenbach, and M. C. Gupta, “Self-organized 2D periodic arrays of nanostructures in silicon by nanosecond laser irradiation”
Applied Optics, Vol. 50, Issue 16, pp. 2349-2355 (2011
2. Z. Li, B. K. Nayak, V. V. Iyengar, D. McIntosh, Q. Zhou, M. C. Gupta and
J. C. Campbell, “Laser-textured silicon photodiode with broadband spectral
response”, Applied Optics, Vol. 50, pp. 2508-2511 (2011)
3. V. Iyengar, B. K. Nayak, K. L. More, H. M. Meyer, M. D. Biegalski, J. V. Li
and M. C. Gupta, “Properties of ultrafast laser textured silicon for
photovoltaics”, Solar Energy Materials and Solar Cells, Vol. 95, 2011, 2745
4.C. N. Sun, E. A. Payzant and M. C. Gupta, "Effect of laser sintering on TiZrB2 mixtures”, J. of the American Ceramic Society, Vol. 94, 3282, 2011
5. C. N. Sun, M. C. Gupta and W. D. Porter, “Thermophysical properties of
laser-sintered Zr–ZrB2 cermets” Journal of the American Ceramic Society,
Vol. 94, 2592 (2011)
6. V. V. Iyengar, B. K. Nayak and M. C. Gupta, “Optical properties of silicon
light trapping structures for photovoltaics”, Solar energy Materials and Solar
Cells, 94, 2251 (2010).
1.
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Laser Based Manufacturing
•Laser Material Interactions
•Process sensing, monitor and control
•Materials and metallurgical aspects
•Laser systems
•Optics and beam delivery systems
•Laser micromachining, welding, plasma processing
and hybrid processes
•Micromachining. Welding, texturing, drilling, surface
modification, cladding, shaping, alloying, cleaning,
sintering
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Research Infrastructure
• Laser and Optics Lab
–
–
–
–
–
–
Two fiber lasers (IPG), 50 ns pulse width
High power CW diode laser (250W)
Fs laser
Two Nd-YAG laser (10 ns pulse width
Optical measurement equipment
Computer controlled stages and galvo systems
• Clean Room Facility for Microfabrication
– Optical Lithography, e-Beam Lithography, sputtering, ebeam deposition, ion etching
• Characterization Facility- SEM, TEM, AFM, X-ray…..
• Sensor and Photovoltaic Device Fabrication and
Characterization Labs
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
IPG fiber laser
Diode laser
Diode pump Solid state laser
YAG laser
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
YAG laser
UNIVERSITY OF VIRGINIA
Laser Texture-Experimental Setup
Wavelength: 800 nm
Pulse Repetition Rate: 1 KHz
Pulse Energy: 1 mJ
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Laser Textured Surfaces
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Applications
• Generation of large surface area
• Light trapping properties
– High contrast marking, logos, serial #’s etc
– Super hydrophobic
– Thermal management
– Surface texture, ice formation, flow
– Bond strength improvement
– Photovoltaics, bio-implants etc.
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Applications
Laser
microma
chining
Laser surface cleaning
Laser sintering
Laser notch
formation
Laser texturing
1 μm
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Technology Transfer
Laser Imaging of Weld Pool Surface
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Technology Transfer
Hybrid Laser-UltraLight Steel Auto Body (ULSAB) Project
• In order to reduce the weight of passenger vehicles,
improve the fuel efficiency and safety, more and more
galvanized steels high-strength steels have been used in
the automotive industry.
• This new welding procedure combines the laser welding
with the gas tungsten arc welding (GTAW) used as a
preheating source has been successfully developed to lap
join the galvanized dual phase steels in a gap-free
configuration.
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Technology Transfer
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
Technology Transfer
• Welding titanium tubes in military aircraft is an exceedingly
critical and very difficult task. Ordinarily this process is
accomplished by manufacturing in super clean operational
environments using high-skilled personnel. The U.S. military will
like to avoid using some of the chemicals traditionally used to
clean titanium tubes prior to welding.
• Working with the Center for Lasers and Plasmas for Advanced
Manufacturing, the U.S. military has demonstrated that surfaces
of titanium tubes can be successfully cleaned using lasers instead
of caustic and environmentally harmful chemicals, thus
successfully removing the oxidation layer and any contaminants
on the outside of the tube.
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
BROCHURE
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
CONCLUSIONS
•Lasers provide a competitive edge in manufacturing
•Significant growth is expected in Laser Based
Manufacturing
•Benefits by UVa Collaboration:
•a long experience in laser based manufacturing and
interaction with industry
•Excellent infrastructure in lasers, optics and
materials/process analysis
•Educational/training in area of laser technology and
its applications in manufacturing
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA
THANK YOU
CHARLES L. BROWN DEPT. OF ELECT. & COMP. ENGR.
UNIVERSITY OF VIRGINIA