Investigation of the Impact of Micro-Structuring on the Bonding Performance of Beechwood (Fagus Sylvatica L.)

Although glueing softwood is well mastered by the industry, predicting and controlling bond quality for hardwood is still challenging after years of research. Parameters such as the adhesive type, resin–hardener ratio, and the penetration behaviour of the wood are determinants for the bond quality. The aim of this work was to assess to what extent the glueing behaviour of beechwood can be improved by using structural planing. The different surfacing methods were characterised by their roughness. The bond strength of the micro-structured surfaces was determined according to EN 302-1, and the delamination resistance was tested as indicated by EN 302-2 for type I adhesives. Micro-structured surfaces were compared with different surfaces (generated by surfacing methods such as dull/sharp planing and sanding). In dry test conditions, all surfacing methods gave satisfying results. In the wet stage, the bond strength on the finer micro-structured surface slightly outperformed the coarse structure surface. For the delamination resistance, a clear improvement could be observed for melamine-formaldehyde-bonded specimens since, when using the recommended amount of adhesive, micro-structured surfaces fulfilled the requirements. Nevertheless, structural planing cannot lead to a reduction in the applied grammage since no sample with a smaller amount fulfilled EN 302-2 requirements even by observing the recommended closed assembly waiting time. Adhesion area enlargement of the micro-structuring is minor. The good delamination performance without waiting time (CAT) is not caused by surface enlargement, since finer micro-structured surface with negligible area increase and delivered even better delamination resistance. Subsurface analysis should be carried out to thoroughly investigate this phenomenon.

Polyamide 6-Aluminum Assembly Enhanced by Laser Microstructuring

The presented work’s aim is the application of low-power laser treatment for the enhancement of interfacial micromechanical adhesion between polyamide 6 (filled with glass fiber) and aluminum. A fiber laser beam was used to prepare micro-patterns on aluminum sheets. The micro-structuring was conducted in the regime of 50, 100, 200 and 300 mm/s laser beam speeds, for both sides. The joining process was realized in an injection molding process. Metallic inserts were surface engraved and overmolded in one-side and two-side configurations. A lap shear test was used to examine the strength of the joints. Engraved metallic surfaces and adequate imprints on polyamide side were checked by optical microscope with motorized stages, and roughness parameters were also determined. Microscopic observations made it possible to describe the grooves’ shape and to conclude that a huge recast melt was formed when the lowest laser beam speed was applied; thus, the roughness parameter Ra reached the highest value of 16.8 μm (compared to 3.5 μm obtained for the fastest laser speed). The maximum shear force was detected for a sample prepared with the lowest scanning speed (one-sides joints), and it was 883 N, while for two-sided joints, the ultimate force was 1410 N (for a scanning speed of 200 mm/s).

Fabrication of micro-structured tools for the production of curved metal surfaces by pulsed electrochemical machining

A new, scalable process chain for the fabrication of curved micro-structured metallic tools is developed and evaluated. Arrays of arrows, circles, semicircles and rings with final lateral dimensions of 124 to 819 µm are realised on the tools and successfully transmitted in one process step to stainless steel workpieces with a functional area of 6.5 cm2 using pulsed electrochemical machining. Photolithography-etching or micromilling are applied as initial micro-structuring processes, resulting in micro-structured master forms. These forms are copied into reusable silicon forms. This is followed by epoxy casting and electroforming to obtain the final tools. The tools are made of Nickel and have a diameter of 34 mm. Whilst micromilling, photolithography, silicon casting, epoxy casting and electroforming copy the structures very precisely, the wet etching process induces a widening of the dimensions due to the isotropic character of the process. The advantage of the process chain is the reusability of the master as well as of the silicone forms, which can be copied very precisely and easily with scalable processes to get precision tools with relatively large micro-structured areas. The reusability of the forms makes the fabrication of micro-structured tools relatively cost-efficient. The use of photolithography as the initial structuring process enables the generation of arbitrary, user-defined geometries for the micro-structures on the tool surface. The process chain described has the potential to fabricate lateral structure sizes on tools down to one micrometre.

Combined nano and micro structuring for enhanced radiative cooling and efficiency of photovoltaic cells

Outdoor devices comprising materials with mid-IR emissions at the atmospheric window (8–13 μm) achieve passive heat dissipation to outer space (~ − 270 °C), besides the atmosphere, being suitable for cooling applications. Recent studies have shown that the micro-scale photonic patterning of such materials further enhances their spectral emissivity. This approach is crucial, especially for daytime operation, where solar radiation often increases the device heat load. However, micro-scale patterning is often sub-optimal for other wavelengths besides 8–13 μm, limiting the devices’ efficiency. Here, we show that the superposition of properly designed in-plane nano- and micro-scaled periodic patterns results in enhanced device performance in the case of solar cell applications. We apply this idea in scalable, few-micron-thick, and simple single-material (glass) radiative coolers on top of simple-planar Si substrates, where we show an ~ 25.4% solar absorption enhancement, combined with a ~ ≤ 5.8 °C temperature reduction. Utilizing a coupled opto-electro-thermal modeling we evaluate our nano-micro-scale cooler also in the case of selected, highly-efficient Si-based photovoltaic architectures, where we achieve an efficiency enhancement of ~ 3.1%, which is 2.3 times higher compared to common anti-reflection layers, while the operating temperature of the device also decreases. Besides the enhanced performance of our nano-micro-scale cooler, our approach of superimposing double- or multi-periodic gratings is generic and suitable in all cases where the performance of a device depends on its response on more than one frequency bands.

Contact Guidance Effect and Prevention of Microfouling on a Beta Titanium Alloy Surface Structured by Electron-Beam Technology

Nano- and micro-structuring of implantable materials constitute a promising approach to introduce mechanical contact guidance effect, drive cells colonization, as well as to prevent bacteria adhesion and biofilm aggregation, through antifouling topography. Accordingly, this paper aims to extend the application of e-beam surface texturing and nano-structuring to the beta titanium alloys, which are of great interest for biomedical implants because of the low Young modulus and the reduction of the stress shielding effect. The paper shows that surface texturing on the micro-scale (micro-grooves) is functional to a contact guidance effect on gingival fibroblasts. Moreover, nano-structuring, derived from the e-beam surface treatment, is effective to prevent microfouling. In fact, human fibroblasts were cultivated directly onto grooved specimens showing to sense the surface micro-structure thus spreading following the grooves’ orientation. Moreover, Staphylococcus aureus colonies adhesion was prevented by the nano-topographies in comparison to the mirror-polished control, thus demonstrating promising antifouling properties. Furthermore, the research goes into detail to understand the mechanism of microfouling prevention due to nano-topography and microstructure.

Simultaneous Micro-Structuring and Surface Smoothing of Additive Manufactured Parts Using DLIP Technique and Its Influence on the Wetting Behaviour

It is well known that the surface topography of a part can affect its function as well as its mechanical performance. In this context, we report on the surface modification of additive manufactured components made of Titanium 64 and Scalmalloy®, using Direct Laser Interference Patterning technique. In our experiments, a nanosecond-pulsed near-infrared laser source with a pulse duration of 10 ns was used. By varying the process parameters, periodic structures with different depths and associated roughness values are produced. Additionally, the influence of the resultant morphological characteristics on the wettability behaviour of the fabricated textures is investigated by means of contact angle measurements. The results demonstrated a reduction of the surface roughness of the additive manufactured parts (in the order of some tens of micrometres) and simultaneously the production of well-defined micro-patterns (in the micrometre range), which allow the wettability of the surfaces from 26° and 16° up to 93° and 131° to be tuned for Titanium 6Al 4V and Al-Mg-Sc (Scalmalloy®), respectively.

Backward Flux Re-Deposition Patterns during Multi-Spot Laser Ablation of Stainless Steel with Picosecond and Femtosecond Pulses in Air

We report on novel observations of directed re-deposition of ablation debris during the ultrafast laser micro-structuring of stainless steel in the air with multi-beams in close proximity on the surface. This interesting phenomenon is observed with both 10 ps and 600 fs NIR laser pulses at 5 kHz repetition rate. Ablation spot geometries could be altered with the use of beam splitting optics or a phase-only Spatial Light modulator. At low fluence (F ~ 1.0 J cm−2) and pulse exposure of a few hundred pulses, the debris appears as concentrated narrow “filaments” connecting the ablation spots, while at higher fluence, (F ~ 5.0 J cm−2) energetic jets of material emanated symmetrically along the axes of symmetry, depositing debris well beyond the typical re-deposition radius with a single spot. Patterns of backward re-deposition of debris to the surface are likely connected with the colliding shock waves and plasma plumes with the ambient air causing stagnation when the spots are in close proximity. The 2D surface debris patterns are indicative of the complex 3D interactions involved over wide timescales during ablation from picoseconds to microseconds.

Laser–Material Interactions of High-Quality Ultrashort Pulsed Vector Vortex Beams

Diffractive multi-beams based on 1 × 5 and 2 × 2 binary Dammann gratings applied to a spatial light modulator (SLM) combined with a nanostructured S-wave plate have been used to generate uniform multiple cylindrical vector beams with radial and azimuthal polarizations. The vector quality factor (concurrence) of the single vector vortex beam was found to be C = 0.95 ± 0.02, hence showing a high degree of vector purity. The multi-beams have been used to ablate polished metal samples (Ti-6Al-4V) with laser-induced periodic surface structures (LIPSS), which confirm the polarization states unambiguously. The measured ablation thresholds of the ring mode radial and azimuthal polarizations are close to those of a Gaussian mode when allowance is made for the expected absolute intensity distribution of a ring beam generated from a Gaussian. In addition, ring mode vortex beams with varying orbital angular momentum (OAM) exhibit the same ablation threshold on titanium alloy. Beam scanning with ring modes for surface LIPSS formation can increase micro-structuring throughput by optimizing fluence over a larger effective beam diameter. The comparison of each machined spot was analysed with a machine learning method—cosine similarity—which confirmed the degree of spatial uniformity achieved, reaching cosθ > 0.96 and 0.92 for the 1 × 5 and 2 × 2 arrays, respectively. Scanning electron microscopy (SEM), optical microscopy and white light surface profiling were used to characterize and quantify the effects of surface modification.