This thesis is concerned with sensitivity alterations of Fiber Bragg Grating (FBG), sensors through additive coatings produced by a combined Laser-Assisted Maskless Micro-deposition (LAMM) and electroless plating process. The coatings can also protect the brittle FBG used in harsh environments. The thesis encompasses design, fabrication procedures, modeling and comparison of experimental and modeling results to gain insight into the advantages and short-comings of the approach. Starting with the opto-mechanical modeling, a program is written in MAPLE to analyze the effect of different on-fiber metallic materials and coating thicknesses on the sensitivity of FBGs to temperature and axial force. On the basis of the proper material and thickness, the sensitivity of FBG at different thermal and loading strains are predicted. The optimal theoretical data suggests that if the thickness of the Ni layer is 30–50 μm, maximum temperature sensitivity is achieved. Some experiments are proposed to test the feasibility of the coated FBG sensors. LAMM is used to coat bare FBGs with a 1-2 μm thick conductive silver layer followed by the electroless nickel plating process to increase layer thickness to a desired level ranging from 1 to 80 μm. Our analytical and experimental results suggest that the temperature sensitivity of the coated FBG with 1 μm Ag and 33 μm Ni is increased almost twice compared to a bare FBG with sensitivity of 0.011±0.001 nm/°C. On the contrary, the force sensitivity is decreased; however, this sensitivity reduction is less than values reported in the literature.

This thesis is concerned with sensitivity alterations of Fiber Bragg Grating (FBG), sensors through additive coatings produced by a combined Laser-Assisted Maskless Micro-deposition (LAMM) and electroless plating process. The coatings can also protect the brittle FBG used in harsh environments. The thesis encompasses design, fabrication procedures, modeling and comparison of experimental and modeling results to gain insight into the advantages and short-comings of the approach. Starting with the opto-mechanical modeling, a program is written in MAPLE to analyze the effect of different on-fiber metallic materials and coating thicknesses on the sensitivity of FBGs to temperature and axial force. On the basis of the proper material and thickness, the sensitivity of FBG at different thermal and loading strains are predicted. The optimal theoretical data suggests that if the thickness of the Ni layer is 30–50 μm, maximum temperature sensitivity is achieved. Some experiments are proposed to test the feasibility of the coated FBG sensors. LAMM is used to coat bare FBGs with a 1-2 μm thick conductive silver layer followed by the electroless nickel plating process to increase layer thickness to a desired level ranging from 1 to 80 μm. Our analytical and experimental results suggest that the temperature sensitivity of the coated FBG with 1 μm Ag and 33 μm Ni is increased almost twice compared to a bare FBG with sensitivity of 0.011±0.001 nm/°C. On the contrary, the force sensitivity is decreased; however, this sensitivity reduction is less than values reported in the literature.

There is growing demand for micro and meso scale devices with applications in the field of optics, semiconductor and bio-medical fields. In response to this demand, mechanical micro-cutting (e.g. micro-milling) is emerging as a viable alternative to lithography based micromachining techniques. Mechanical micromachining methods are capable of generating three-dimensional free-form surfaces to sub-micron level precision and micron level accuracies in a wide range of materials including common engineering alloys. However, certain factors limit the types of workpiece materials that can be processed using mechanical micromachining methods. For difficult-to-machine materials such as tool and die steels, limited machine-tool system stiffness and low tool flexural strength are major impediments to the use of mechanical micromachining methods. This thesis presents the design, fabrication and analysis of a novel Laser-assisted Mechanical Micromachining (LAMM) process that has the potential to overcome these limitations. The basic concept involves creating localized thermal softening of the hard material by focusing a solid-state continuous wave laser beam of diameter ranging from 70-120 microns directly in front of a miniature (300 microns-1 mm wide) cutting tool. By suitably controlling the laser power, spot size and speed, it is possible to produce a sufficiently large decrease in flow stress of the work material and, consequently, the cutting forces. This in turn will reduce machine/tool deflection and chances of catastrophic tool failure. The reduced machine/tool deflection yields improved accuracy in the machined feature. In order to use this process effectively, adequate thermal softening needs to be produced while keeping the heat affected zone in the machined surface to a minimum. This has been accomplished in the thesis via a detailed process characterization, modeling of process mechanics and optimization of process variables.

Laser-assisted machining has been considered as an alternative for difficult-to-machine materials such as metallic alloys and ceramics. Machining of some materials such as high chromium alloys and high strength steels is still a delicate and challenging task. Conventional machines or computer numerical control (CNC) machines and cutting tools cannot adapt easily to such materials and induce very high costs for operations of rough machining or finishing. If laser-assisted machining can be implemented successfully for such materials, it will offer several advantages over the traditional methods including longer tool life, shorter machining time and reduced overall costs. This thesis presents the results of the research conducted on laser assisted machining of hard to wear materials used in making heavy duty mineral processing equipment for the mining industry. Experimental set up using a high power Nd:YAG laser beam attached to a lathe has been developed to machine these materials using cubic boron nitride (CBN) based cutting tools. The laser beam was positioned so that it was heating a point on the surface of the workpiece directly before it passed under the cutting tool. Cutting forces were measured during laser assisted machining and were compared to those measured during conventional machining. Results from the experiments show that with the right cutting parameters and laser beam position, laser assisted machining results in a reduction in cutting forces compared to conventional machining. A mathematical thermal model was used to predict temperatures within the workpiece at depths under the laser beam spot. The model was used to determine the effect of various cutting and laser parameters on the temperature profile within the workpiece. This study shows that laser assisted machining of hard to wear materials such as high chromium white cast iron shows potential as a possible economical alternative to conventional machining methods. Further research is needed before it can be introduced in industry as an alternative to conventional machining.

<p>Thin films of refractory metals and carbides have been studied extensively over many years because of their wide range of application. The two major techniques used are Chemical Vapour Deposition (CVD) and Physical Vapour Deposition (PVD). These can result in the deposition of two-dimensional blanket or patterned thin films. Laser-assisted Chemical Vapour Deposition (LCVD) can provide a maskless alternative for localised deposition in two and three dimensions. This thesis describes LCVD of micrometer-sized tungsten, molybdenum and tungsten carbide rods. The kinetics, phase composition and microstructure have been studied as a function of in situ measured laser induced deposition temperature.</p><p>Tungsten and molybdenum rods were deposited by hydrogen reduction of their corresponding hexafluorides, WF6 and MoF6, respectively. Single crystal and polycrystalline tungsten rods were obtained, depending on the H2/WF6 molar ratio and deposition temperature. The molybdenum rods were either single crystals or dendritic in form depending on experimental conditions. The field emission characteristics of the tungsten single crystals were investigated. The results showed LCVD to be a potential fabrication technique for field emitting cathodes.</p><p>Nanocrystalline tungsten carbide rods were deposited from WF6, C2H4 and H2. TEM analysis showed that the carbide rods exhibited a layered structure in terms of phase composition and grain size as a result of the temperature gradient induced by the laser beam. With decreasing WF6/C2H4 molar ratio, the carbon content in the rods increased and the phase composition changed from W/W2C to WC/WC1-x and finally to WC1-x/C.</p>

<p>One important driving force in nanotechnology today is the change which can be made in the properties of a material when the dimensions of its individual building blocks are decreased below approximately 100 nm. Such small building blocks, typically nanoparticles, may induce new and unique properties compared to those of the corresponding bulk material. The challenge in nanotechnology is to make nanoparticles with a discrete particle size within the range 1-10 nm. It is also important to develop appropriate assembly methodologies in order to construct devices composed of such small building blocks.</p><p>This thesis reports iron nanoparticle synthesis using laser-assisted photolysis of ferrocene. The particles were protected against oxidation by a carbon shell formed in situ during their growth. By varying the experimental conditions such as fluence, repetition rate and laser beam area, particles could be synthesized in the size range 1 to 100 nm. Their size was measured using a differential mobility analyser (DMA), transmission electron microscopy (TEM) and X-ray diffraction (XRD). DMA was also used successfully to size-select particles to facilitate the deposition of monodisperse nanoparticle films.</p><p>A theoretical "residence time approach (RTA)" model was developed to relate particle volume to the laser parameters used. The growth of these particles was studied in situ using optical emission spectroscopy; the results were compared with those from quantum mechanical calculations. The particles were characterised ex situ by TEM, convergent beam electron diffraction, XRD, X-ray photoelectron spectroscopy and Raman spectroscopy. Results from the TEM investigations revealed that the carbon shell was graphitic close to the iron core, while the outer part of the carbon shell was amorphous, indicating different growth mechanisms. Both bcc and fcc iron particles were observed. </p>

Thin films of refractory metals and carbides have been studied extensively over many years because of their wide range of application. The two major techniques used are Chemical Vapour Deposition (CVD) and Physical Vapour Deposition (PVD). These can result in the deposition of two-dimensional blanket or patterned thin films. Laser-assisted Chemical Vapour Deposition (LCVD) can provide a maskless alternative for localised deposition in two and three dimensions. This thesis describes LCVD of micrometer-sized tungsten, molybdenum and tungsten carbide rods. The kinetics, phase composition and microstructure have been studied as a function of in situ measured laser induced deposition temperature. Tungsten and molybdenum rods were deposited by hydrogen reduction of their corresponding hexafluorides, WF6 and MoF6, respectively. Single crystal and polycrystalline tungsten rods were obtained, depending on the H2/WF6 molar ratio and deposition temperature. The molybdenum rods were either single crystals or dendritic in form depending on experimental conditions. The field emission characteristics of the tungsten single crystals were investigated. The results showed LCVD to be a potential fabrication technique for field emitting cathodes. Nanocrystalline tungsten carbide rods were deposited from WF6, C2H4 and H2. TEM analysis showed that the carbide rods exhibited a layered structure in terms of phase composition and grain size as a result of the temperature gradient induced by the laser beam. With decreasing WF6/C2H4 molar ratio, the carbon content in the rods increased and the phase composition changed from W/W2C to WC/WC1-x and finally to WC1-x/C.

One important driving force in nanotechnology today is the change which can be made in the properties of a material when the dimensions of its individual building blocks are decreased below approximately 100 nm. Such small building blocks, typically nanoparticles, may induce new and unique properties compared to those of the corresponding bulk material. The challenge in nanotechnology is to make nanoparticles with a discrete particle size within the range 1-10 nm. It is also important to develop appropriate assembly methodologies in order to construct devices composed of such small building blocks. This thesis reports iron nanoparticle synthesis using laser-assisted photolysis of ferrocene. The particles were protected against oxidation by a carbon shell formed in situ during their growth. By varying the experimental conditions such as fluence, repetition rate and laser beam area, particles could be synthesized in the size range 1 to 100 nm. Their size was measured using a differential mobility analyser (DMA), transmission electron microscopy (TEM) and X-ray diffraction (XRD). DMA was also used successfully to size-select particles to facilitate the deposition of monodisperse nanoparticle films. A theoretical "residence time approach (RTA)" model was developed to relate particle volume to the laser parameters used. The growth of these particles was studied in situ using optical emission spectroscopy; the results were compared with those from quantum mechanical calculations. The particles were characterised ex situ by TEM, convergent beam electron diffraction, XRD, X-ray photoelectron spectroscopy and Raman spectroscopy. Results from the TEM investigations revealed that the carbon shell was graphitic close to the iron core, while the outer part of the carbon shell was amorphous, indicating different growth mechanisms. Both bcc and fcc iron particles were observed.

High-power diode lasers (HPDL) are being increasingly used in industrial applications. Deposition of nickel from nickel carbonyl (Ni(CO)4) precursor by laser-induced chemical vapor deposition (CVD) was studied with emphasis on achieving high deposition rates. An HPDL system was used to provide a novel energy source facilitating a simple and compact design of the energy delivery system. Nickel deposits on complex, 3-dimensional polyurethane foam substrates were prepared and characterized. The resulting “nickel foam” represents a novel material of high porosity (>95% by volume) finding uses, among others, in the production of rechargeable battery and fuel cell electrodes and as a specialty high-temperature filtration medium. Deposition rates up to ~19 µm/min were achieved by optimizing the gas precursor flow pattern and energy delivery to the substrate surface using a 480W diode laser. Factors affecting the transition from purely heterogeneous decomposition to a combined hetero- and homogeneous decomposition of nickel carbonyl were studied. High quality, uniform 3-D deposits produced at a rate more than ten times higher than in commercial processes were obtained by careful balance of mass transport (gas flow) and energy delivery (laser power). Cross-flow of the gases through the porous substrate was found to be essential in facilitating mass transport and for obtaining uniform deposits at high rates. When controlling the process in a transient regime (near the onset of homogenous decomposition), unique morphology features formed as part of the deposits, including textured surface with pyramid-shape crystallites, spherical and non-spherical particles and filaments. Operating the laser in a pulsed mode produced smooth, nano-crystalline deposits with sub-100 nm grains. The effect of H2S, a commonly used additive in nickel carbonyl CVD, was studied using both polyurethane and nickel foam substrates. H2S was shown to improve the substrate coverage and deposit uniformity in tests with polyurethane substrate, however, it was found to have no effect in improving the overall deposition rate compared to H2S-free deposition process. Deposition on other selected substrates, such as ultra-fine polymer foam, carbon nanofoam and multi-wall carbon nanotubes, was demonstrated. The HPDL system shows good promise for large-scale industrial application as the cost of HPDL energy continues to decrease.

High-power diode lasers (HPDL) are being increasingly used in industrial applications. Deposition of nickel from nickel carbonyl (Ni(CO)4) precursor by laser-induced chemical vapor deposition (CVD) was studied with emphasis on achieving high deposition rates. An HPDL system was used to provide a novel energy source facilitating a simple and compact design of the energy delivery system. Nickel deposits on complex, 3-dimensional polyurethane foam substrates were prepared and characterized. The resulting “nickel foam” represents a novel material of high porosity (>95% by volume) finding uses, among others, in the production of rechargeable battery and fuel cell electrodes and as a specialty high-temperature filtration medium. Deposition rates up to ~19 µm/min were achieved by optimizing the gas precursor flow pattern and energy delivery to the substrate surface using a 480W diode laser. Factors affecting the transition from purely heterogeneous decomposition to a combined hetero- and homogeneous decomposition of nickel carbonyl were studied. High quality, uniform 3-D deposits produced at a rate more than ten times higher than in commercial processes were obtained by careful balance of mass transport (gas flow) and energy delivery (laser power). Cross-flow of the gases through the porous substrate was found to be essential in facilitating mass transport and for obtaining uniform deposits at high rates. When controlling the process in a transient regime (near the onset of homogenous decomposition), unique morphology features formed as part of the deposits, including textured surface with pyramid-shape crystallites, spherical and non-spherical particles and filaments. Operating the laser in a pulsed mode produced smooth, nano-crystalline deposits with sub-100 nm grains. The effect of H2S, a commonly used additive in nickel carbonyl CVD, was studied using both polyurethane and nickel foam substrates. H2S was shown to improve the substrate coverage and deposit uniformity in tests with polyurethane substrate, however, it was found to have no effect in improving the overall deposition rate compared to H2S-free deposition process. Deposition on other selected substrates, such as ultra-fine polymer foam, carbon nanofoam and multi-wall carbon nanotubes, was demonstrated. The HPDL system shows good promise for large-scale industrial application as the cost of HPDL energy continues to decrease.