Comparative Multi-Modal, Multi-Scale Residual Stress Evaluation in SLM 3D-Printed Al-Si-Mg Alloy (RS-300) Parts

SLM additive manufacturing has demonstrated great potential for aerospace applications when structural elements of individual design and/or complex shape need to be promptly supplied. 3D-printable AlSi10Mg (RS-300) alloy is widely used for the fabrication of different structures in the aerospace industry. The importance of the evaluation of residual stresses that arise as a result of the 3D-printing process’ complex thermal history is widely discussed in literature, but systematic assessment remains lacking for their magnitude, spatial distribution, and comparative analysis of different evaluation techniques. In this study, we report the results of a systematic study of residual stresses in 3D-printed double tower shaped samples using several approaches: the contour method, blind hole drilling laser speckle interferometry, X-ray diffraction, and Xe pFIB-DIC micro-ring-core milling analysis. We show that a high level of tensile and compressive residual stresses is inherited from SLM 3D-printing and retained for longer than 6 months. The stresses vary (from −80 to +180 MPa) over a significant proportion of the material yield stress (from −⅓ to ¾). All residual stress evaluation techniques considered returned comparable values of residual stresses, regardless of dramatically different dimensional scales, which ranged from millimeters for the contour method, laser speckle interferometry, and XRD down to small fractions of a mm (70 μm) for Xe pFIB-DIC ring-core drilling. The use of residual stress evaluation is discussed in the context of optimizing printing strategies to enhance mechanical performance and long-term durability.

Comparative Residual Stress Evaluation in SLM 3D-printed Al-Si-Mg alloy (RS-300) Using the Contour Method, Hole Drilling Laser Speckle Interferometry, X-ray Diffraction and Xe pFIB-DIC Micro-ring-core Milling

SLM Additive Manufacturing has demonstrated great potential for aerospace applications when structural elements of individual design and/or complex shape need to be promptly supplied. 3D-printable AlSi10Mg (RS-300) alloy is widely used for the fabrication of different structures in aerospace industry. The importance of the evaluation of residual stresses that arise as a result of complex 3D-printing process thermal history is widely discussed in literature, but systematic assessment remains lacking for their magnitude, spatial distribution, and comparative analysis of different evaluation techniques. In this study we report the results of a systematic study of residual stresses in a 3D-printed double tower shaped samples using several approaches: the contour method, blind hole drilling laser speckle interferometry, X-ray diffraction, and Xe pFIB-DIC micro-ring-core milling analysis. We show that a high level of tensile and compressive residual stresses is inherited from SLM 3D-printing and retained for longer than 6 months. The stresses vary over a significant proportion of the material yield stress. All residual stress evaluation techniques considered returned comparable values of residual stresses even regardless of dramatically different dimensional scales from millimeters for the Contour Method down, laser speckle interferometry and XRD and down to small fractions of a mm (70 μm) for Xe pFIB-DIC ring-core drilling. The use of residual stress evaluation is discussed in the context of optimizing the printing strategy to enhance the mechanical performance and long-term durability.

Photonic integrated chip enabling orbital angular momentum multiplexing for quantum communication

Light carrying orbital angular momentum constitutes an important resource for both classical and quantum information technologies. Its inherently unbounded nature can be exploited to generate high-dimensional quantum states or for channel multiplexing in classical and quantum communication in order to significantly boost the data capacity and the secret key rate, respectively. While the big potentials of light owning orbital angular momentum have been widely ascertained, its technological deployment is still limited by the difficulties deriving from the fabrication of integrated and scalable photonic devices able to generate and manipulate it. Here, we present a photonic integrated chip able to excite orbital angular momentum modes in an 800 m long ring-core fiber, allowing us to perform parallel quantum key distribution using two and three different modes simultaneously. The experiment sets the first steps towards quantum orbital angular momentum division multiplexing enabled by a compact and light-weight silicon chip, and further pushes the development of integrated scalable devices supporting orbital angular momentum modes.

Generation, Transmission and Application of Orbital Angular Momentum in Optical Fiber: A Review

Optical orbital angular momentum (OAM) has become a hot research topic because of its unique properties due to its spiral distribution of phases. The production and transmission of OAM has also become a necessary condition for effective use of OAM. As an optical waveguide with good propagation properties, optical fibers are used in optical systems supporting OAM. This paper introduces the OAM generation and transmission system based on fiber, summarizes the current photonic crystal fiber, ring core fiber, fiber grating and other all-fiber systems that can support OAM modes, and explains some experimental principles. Finally, an outlook on OAM generation or transmission devices for all-fiber systems is presented, providing a useful reference for future related research.

SDM transmission of orbital angular momentum mode channels over a multi-ring-core fibre

Spatial division multiplexed optical transmission over a multi-ring-core orbital angular momentum (OAM) fibre is reported for the first time. The seven cores in the fibre each supports OAM modes belonging to mode groups (MGs) of topological charge |l| = 0–4. The MGs of |l| = 1–4 each contains four near-degenerate OAM modes that carry the combinations of opposite orbital and spin angular momenta. The weak coupling between these higher-order MGs as well as between the cores enables the simultaneous transmission of 56 OAM mode channels (two MGs per core of the topological charges |l| = 2 and 3) over the 60-km span, while only requiring modular 4 × 4 multi-input multi-output (MIMO) signal processing to equalize the mixing among the four mode channels in each MG that are strongly coupled – a feature that also minimizes the number of filter taps. The mode channels are launched using seven-core single-mode fibre fan-in devices, with the light in all seven cores converted into OAM modes via specially designed plates that carry seven off-axis-compensated phase masks matching the hexagonal configuration of the multi-core fibres. Each mode channel carries 10 WDM wavelengths, equivalently aggregating to a capacity of 31.4 Tbit/s (net 25.1 Tb/s) and a spectral efficiency (SE) of 62.7 bit/s/Hz (net 50.2 bit/s/Hz) with 28-GBaud QPSK modulation per data channel.