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The excellent pseudoelasticity, shape memory and biocompatibility of Nitinol have made it a leading candidate for applications in various fields, including aerospace, micro-electronics and medical devices. Challenges associated with laser processing need to be resolved before its full potential in practical applications can be realized. The current thesis details the effects of pulsed Nd:YAG laser processing on Ni-rich (Ni-49.2. at.% Ti) Nitinol. First, the mechanical, pseudoelastic and cyclic loading properties for varying process parameters have been compared to those of the base metal. Process parameters were shown to greatly influence the mechanical performance. This was due to local yielding occurring within the processed material during tensile straining. In addition, laser processed samples showed higher permanent residual strain and exhibited a slightly higher efficiency for energy storage during the initial 5 cycles compared to base material. Fracture surfaces of base material revealed ductile dimpled surfaces while welded specimens exhibited both brittle (low peak power) and ductile (high peak power) failure modes. DSC analyses conducted on the processed metal revealed additional high temperature transformation peaks. These peaks were attributed to the local phase conversion induced by laser processing. Further corroboration was made with room temperature XRD analysis, showing only austenite in the base metal and added martensite peaks in the melted metal. Temperature controlled TEM observations confirmed high temperature transformation peaks to be associated with processed metal. Furthermore, TEM analysis aided in identifying the submicron second phase particles observed in fracture surfaces as Ti2Ni. Finally, local phase conversion was correlated to change in local chemical composition. Preferential vaporization of nickel was determined to cause the change in Ni/Ti ratio. This in turn explained the altered mechanical performance and presence of the Ti-rich intermetallic (Ti2Ni). Consequently, a novel method using a high power density energy source to alter transformation temperature of shape memory alloys (SMA’s) was developed. Results were used to successfully demonstrate a novel technology that can embed additional memories in Nitinol and other SMA’s. Possessing the ability to control local transformation temperatures and as a result the shape memory effect of SMA’s promises to enhance their functionality while enabling new applications to be realized.

Laser processing of NiTi shape memory alloys (SMA) has been identified as having great potential in surface treatment, welding, and novel performance requirement applications. However, discrepancies arise regarding whether laser processing improves or degrades the corrosion performance of NiTi-based SMAs. This is a cause for concern over the reliability of the laser processed surfaces. Prior to full scale implementation, a better understanding of oxide evolution during laser processing is required. The first part of this study concerned a systematic investigation of the surface of Ni-44.2 wt.% Ti SMA after the application of differing amounts of laser pulsing and thus energy input. Specific focus was directed on characterizing local changes in the surface oxide adjacent to laser spots. The sample local electrochemical characteristics were investigated by scanning electrochemical microscopy (SECM). The effect of laser processing on the regeneration kinetics of the redox-active mediator was analyzed through microelectrode current maps and approach curves in the feedback mode. Raman spectroscopy was used to determine the crystallinity of the oxide and potentiodynamic cyclic polarization was used to determine oxide stability. Results showed that for a small number of pulses (i.e. low total energy input) corrosion performance was determined primarily by topographical effects. However, increasing the number of pulses (i.e. higher total energy input) had a significant impact on the stability of the oxide in the heat-affected zone (HAZ) region due to the increase in crystallinity, which dictated where the corrosion initiated. In the second part of this study, post-process surface treatments that could be applied to NiTi SMA after laser processing were systematically investigated. Specific focus was directed at characterizing the crystallinity of the newly formed oxides and the stability across the entire surface (containing laser-processed regions and retained base material). Raman spectroscopy and potentiodynamic cyclic polarization were used for this analysis. Results showed that the post-process surface treatments successfully restored the corrosion performance to pre-laser-processing conditions by eliminating crystallinity in the surface oxide and reducing inhomogeneity across the surface.

The excellent pseudoelasticity, shape memory and biocompatibility of Nitinol have made it a leading candidate for applications in various fields, including aerospace, micro-electronics and medical devices. Challenges associated with laser processing need to be resolved before its full potential in practical applications can be realized. The current thesis details the effects of pulsed Nd:YAG laser processing on Ni-rich (Ni-49.2. at.% Ti) Nitinol. First, the mechanical, pseudoelastic and cyclic loading properties for varying process parameters have been compared to those of the base metal. Process parameters were shown to greatly influence the mechanical performance. This was due to local yielding occurring within the processed material during tensile straining. In addition, laser processed samples showed higher permanent residual strain and exhibited a slightly higher efficiency for energy storage during the initial 5 cycles compared to base material. Fracture surfaces of base material revealed ductile dimpled surfaces while welded specimens exhibited both brittle (low peak power) and ductile (high peak power) failure modes. DSC analyses conducted on the processed metal revealed additional high temperature transformation peaks. These peaks were attributed to the local phase conversion induced by laser processing. Further corroboration was made with room temperature XRD analysis, showing only austenite in the base metal and added martensite peaks in the melted metal. Temperature controlled TEM observations confirmed high temperature transformation peaks to be associated with processed metal. Furthermore, TEM analysis aided in identifying the submicron second phase particles observed in fracture surfaces as Ti2Ni. Finally, local phase conversion was correlated to change in local chemical composition. Preferential vaporization of nickel was determined to cause the change in Ni/Ti ratio. This in turn explained the altered mechanical performance and presence of the Ti-rich intermetallic (Ti2Ni). Consequently, a novel method using a high power density energy source to alter transformation temperature of shape memory alloys (SMA’s) was developed. Results were used to successfully demonstrate a novel technology that can embed additional memories in Nitinol and other SMA’s. Possessing the ability to control local transformation temperatures and as a result the shape memory effect of SMA’s promises to enhance their functionality while enabling new applications to be realized.

Possessing unique thermomechanical properties, the discovery of nickel-titanium shape memory alloys (SMAs) has sprouted a plethora of applications in various fields, including aerospace, automotive, microelectronics, and medical devices. Due to its excellent biocompatibility and its ability to mimic biological forces, the medical implant industry has shown strong interest in expanding the application of NiTi SMAs. However, traditional SMA functional properties are limited by a single set of thermomechanical characteristics in a monolithic component. Past efforts in overcoming this limitation have had little success until recently with the invention of the multiple memory material (MMM) processing technology. This novel processing technology enables multiple functional responses through the augmentation of local microstructure and composition using a high power density source such as a laser. This thesis presents an investigation of the effect of laser processing on pseudoelastic behaviour and corrosion response of medical grade SMAs.

Femtosecond laser processes were optimized for nonlinear interactions with optical materials to develop a novel biophotonic lab-on-a-chip device that integrates laser-formed waveguides, microfluidic channels and photonic crystals (PCs). Such integration seeks the novel demonstration of dual PC functionalities: (1) efficient chromatographic separation and filtration of analytes through a porous PC embedded inside a microfluidic channel and (2) optofluidic spectroscopy through embedded waveguides that probe PC stop band shifts as varying analyte concentrations flow and separate. The building blocks for such integration were demonstrated through the accelerated analyte flow rates measured through the embedded porous PC and the optical characterization of a PC’s stop band via integrated waveguides. Together, these laboratory results give promise for achieving simultaneous chromatographic and spectroscopic capabilities in a single PC optofluidic device. Future improvements in the laser process and possible new research directions are also offered.

Femtosecond laser processes were optimized for nonlinear interactions with optical materials to develop a novel biophotonic lab-on-a-chip device that integrates laser-formed waveguides, microfluidic channels and photonic crystals (PCs). Such integration seeks the novel demonstration of dual PC functionalities: (1) efficient chromatographic separation and filtration of analytes through a porous PC embedded inside a microfluidic channel and (2) optofluidic spectroscopy through embedded waveguides that probe PC stop band shifts as varying analyte concentrations flow and separate. The building blocks for such integration were demonstrated through the accelerated analyte flow rates measured through the embedded porous PC and the optical characterization of a PC’s stop band via integrated waveguides. Together, these laboratory results give promise for achieving simultaneous chromatographic and spectroscopic capabilities in a single PC optofluidic device. Future improvements in the laser process and possible new research directions are also offered.

It is well known that typical welding processes such as laser welding are nonlinear although mostly they are treated as linear system. For the purpose of automatic control, Identification of nonlinear system, especially welding processes is a necessary and fundamental problem. The purpose of this research is to develop a simple and practical identification and control for welding processes. Many investigations have shown the possibility to represent physical processes by nonlinear models, such as Hammerstein structure, consisting of a nonlinearity and linear dynamics in series with each other. Motivated by the fact that typical welding processes do not have non-zeroes, a novel two-step nonlinear Hammerstein identification method is proposed for laser welding processes. The method can be realized both in continuous and discrete case. To study the relation among parameters influencing laser processing, a standard diode laser processing system is built as system prototype. Based on experimental study, a SISO and 2ISO nonlinear Hammerstein model structure are developed to approximate the diode laser welding process. Specific persistent excitation signals such as PRTS (Pseudo-random-ternary-series) to Step signal are used for identification. The model takes welding speed as input and the top surface molten weld pool width as output. A vision based sensor implemented with a Pulse-controlled-CCD camera is proposed and applied to acquire the images and the geometric data of the weld pool. The estimated model is then verified by comparing the simulation and experimental measurement. The verification shows that the model is reasonably correct and can be use to model the nonlinear process for further study. The two-step nonlinear identification method is proved valid and applicable to traditional welding processes and similar manufacturing processes. Based on the identified model, nonlinear control algorithms are also studied. Algorithms include simple linearization and backstepping based robust adaptive control algorithm are proposed and simulated.

Mesoporous TiO2 thin film has been considered as a benchmark material in the applications of dye sensitised solar cells (DSSCs) due to a combination of the physical properties that are inherent to the metal oxide and its particular structuring, in addition to its chemical stability and commercial availability. For DSSCs, a more important functionality of mesoporous TiO2 thin films is their extremely high surface and internal surface areas, resulting in high adsorption of dye molecules. However, a major drawback of fabrication of mesoporous TiO2 thin films is its high-temperature furnace sintering at 450à ̄‚°C-500à ̄‚°C for 30 min. The high-temperature process prevents the possibility of integrating different electro-optical devices on the same substrate, and the sintering time required would be a hurdle for potentially rapid manufacturing of mesoporous metal oxide thin films for DSSCs. This thesis demonstrates for the first time the use of a fibre laser with a wavelength of 1070 nm and a pulse width of milliseconds for generation of 1) mesoporous nanocrystalline (nc) TiO2 thin films on ITO coated glass, and 2) compact TiO2 layer and mesoporous TiO2 film on ITO coated glass. The first one was achieved by complete vaporisation of organic binder and inter-connection of TiO2 nanoparticles; and the second one was achieved by full crystallisation of TiO2 precursor to form the compact TiO2 layer and the same sintering process described above. Both processes were one-step, and achieved by stationary laser beam irradiation of 1 minute, compared with 30 min for furnace-sintering to form a mesoporous TiO2 film, and 2 h for two-step furnace treatment to form compact layer and mesoporous film on ITO glass. No thermally damaging of the ITO layers and the glass substrates was observed. The DSSC with the laser-sintered TiO2 photoanode at the optimised laser processing condition of 85 W/cm2 and 100 ms/50 ms pulse mode reached higher power conversion efficiency (PCE) of 3.20% for the TiO2 film thickness of 6 à ̄­m compared with 2.99% for the furnace-sintered; the DSSC with the laser-treated compact TiO2 layer and mesoporous TiO2 film on ITO glass at the optimised laser treatment condition of 85 W/cm2 and 125 ms/25 ms, reached 5.76% compared to 4.83% with the furnace-treated. Electrochemical impedance spectroscopy (EIS) studies revealed that the laser sintering effectively decreased charge transfer resistance and increased electron lifetime of the TiO2 thin films. It is believed that the use of the fibre laser with over 40% wall-plug efficiency offers an economically-feasible, industrial viable solution to the major challenge of rapid fabrication of large scale, mass production of mesoporous metal oxide thin film based solar energy systems, potentially for perovskite and monolithic tandem solar cells, in the future. Another part of the thesis presents a detailed investigation on the improvement of photovoltaic performance of furnace-sintered TiO2 films on ITO-coated glass using an excimer laser with a wavelength of 248 nm and possesses a rectangular beam profile and has a full width at half maximum (FWHM) pulse duration of 13-20 ns. This was achieved by modifying the surface of the furnace-sintered TiO2 films to increase the roughness, which led to increased optical absorbance via light-trapping. The laser process was carried out with variation of laser fluence and number of pulses per unit area. Under the optimised laser fluence of 34 mJ/cm2 and number of pulses of 50, the DSSC with the laser-modified TiO2 photoanode showed a high power conversion efficiency of 2.99% than 2.10% without the laser treatment. EIS studies showed that the films modified under the optimised laser parameter effectively decreased charge transfer resistance and increased electron lifetime of the TiO2 thin films.

abstract: This work explores the application and optimization of laser patterning of dielectrics on textured crystalline silicon for improving the performance of industrial silicon solar cells. Current direct laser patterning processes introduce defects to the surface of the solar cell as a result of the film transparency and the intensity variation of the laser induced by the textured surface. As a means of overcoming these challenges, a co-deposited protective masking film was developed that is directly patterned with laser light at greatly depreciated light intensities that allows for selective chemical etching of the underlying dielectric films without incurring substantial defects to the surface of the device. Initial defects produced by the process are carefully evaluated with electron microscopy techniques and their mechanism for generation is identified and compensated. Further, an analysis of the opening fraction within the laser spot is evaluated –the area of removed film within the laser spot divided by the area of the laser spot– and residue produced by the laser process within the contact opening is studied. Once identified, this non-damaging laser process is a promising alternative to the standard screen print and fire process currently used by industry for metallization of silicon solar cells. Smaller contacts may be made with the laser process that are as of yet unattainable with screen printing, allowing for a decrease in shading losses. Additionally, the use of patterning allows for silver-free metallization and improved conductivity in the contacts, thereby decreasing parasitic losses in the device. / Dissertation/Thesis / Doctoral Dissertation Electrical Engineering 2018