CFRP flexible manufacturing with superior quality and efficiency using a versatile spatially shaped femtosecond laser
As an advanced lightweight structural material, carbon fiber reinforced polymer (CFRP) confronts various complex manufacturing demands for diverse industrial applications. Conventional Gaussian lasers lack adaptive flexibility and call for improvements in processing quality and efficiency. Herein, w...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-05-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425008889 |
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| author | Xueqiang Zhang Xin Li Yunduo Wang Qimeng Song Yiwen Li Kaihu Zhang Mengyao Tian Yibo Lu Xiaorui Li Sumei Wang Lan Jiang |
| author_facet | Xueqiang Zhang Xin Li Yunduo Wang Qimeng Song Yiwen Li Kaihu Zhang Mengyao Tian Yibo Lu Xiaorui Li Sumei Wang Lan Jiang |
| author_sort | Xueqiang Zhang |
| collection | DOAJ |
| description | As an advanced lightweight structural material, carbon fiber reinforced polymer (CFRP) confronts various complex manufacturing demands for diverse industrial applications. Conventional Gaussian lasers lack adaptive flexibility and call for improvements in processing quality and efficiency. Herein, we propose a versatile spatially shaped femtosecond laser flexible processing strategy. Unlike traditional Gaussian lasers, the spatially shaped laser fields with precisely regulated energy distribution, shape and size are tailored for general-purpose CFRP manufacturing while ensuring superior processing quality and efficiency. For selective removal, the energy homogenization and size regulation enable the complete removal of surface resin without damaging the carbon fibers, demonstrating a 33.4-fold increase in effective scanning width. Regarding homogeneous removal, the further U-shaped design effectively suppresses heat transfer to the structural edges, achieving a minimum HAZ of 2.2 μm and a remarkable 96 % reduction. Additionally, the removal volume increases by 2 times and 14 times under identical processing parameters and depths, respectively. Temperature simulations confirm that the removal sizes of resin and carbon fiber are similar under spatially shaped laser field, validating the homogeneous removal mechanism. Through the flexible design and switching of laser fields, several additional CFRP manufacturing cases has been demonstrated. This method shows significant potential for general CFRP manufacturing in various practical engineering applications. |
| format | Article |
| id | doaj-art-56ea141982334a74a400b0b7bec079ff |
| institution | OA Journals |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-56ea141982334a74a400b0b7bec079ff2025-08-20T02:12:08ZengElsevierJournal of Materials Research and Technology2238-78542025-05-01363958397310.1016/j.jmrt.2025.04.067CFRP flexible manufacturing with superior quality and efficiency using a versatile spatially shaped femtosecond laserXueqiang Zhang0Xin Li1Yunduo Wang2Qimeng Song3Yiwen Li4Kaihu Zhang5Mengyao Tian6Yibo Lu7Xiaorui Li8Sumei Wang9Lan Jiang10Laser Micro/Nano-Fabrication Laboratory, School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, ChinaLaser Micro/Nano-Fabrication Laboratory, School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, China; Beijing Institute of Technology Chongqing Innovation Center, Chongqing, 401120, China; Yangtze Delta Region Academy of Beijing Institute of Technology, Jiaxing, 314019, China; Corresponding author. Laser Micro/Nano-Fabrication Laboratory, School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, China.Laser Micro/Nano-Fabrication Laboratory, School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, ChinaLaser Micro/Nano-Fabrication Laboratory, School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, ChinaLaser Micro/Nano-Fabrication Laboratory, School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, ChinaBeijing Spacecrafts, China Academy of Space Technology, Beijing, 100094, ChinaLaser Micro/Nano-Fabrication Laboratory, School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, ChinaLaser Micro/Nano-Fabrication Laboratory, School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, ChinaLaser Micro/Nano-Fabrication Laboratory, School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, ChinaLaser Micro/Nano-Fabrication Laboratory, School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, China; Beijing Institute of Technology Chongqing Innovation Center, Chongqing, 401120, China; Yangtze Delta Region Academy of Beijing Institute of Technology, Jiaxing, 314019, ChinaLaser Micro/Nano-Fabrication Laboratory, School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, China; Beijing Institute of Technology Chongqing Innovation Center, Chongqing, 401120, China; Yangtze Delta Region Academy of Beijing Institute of Technology, Jiaxing, 314019, ChinaAs an advanced lightweight structural material, carbon fiber reinforced polymer (CFRP) confronts various complex manufacturing demands for diverse industrial applications. Conventional Gaussian lasers lack adaptive flexibility and call for improvements in processing quality and efficiency. Herein, we propose a versatile spatially shaped femtosecond laser flexible processing strategy. Unlike traditional Gaussian lasers, the spatially shaped laser fields with precisely regulated energy distribution, shape and size are tailored for general-purpose CFRP manufacturing while ensuring superior processing quality and efficiency. For selective removal, the energy homogenization and size regulation enable the complete removal of surface resin without damaging the carbon fibers, demonstrating a 33.4-fold increase in effective scanning width. Regarding homogeneous removal, the further U-shaped design effectively suppresses heat transfer to the structural edges, achieving a minimum HAZ of 2.2 μm and a remarkable 96 % reduction. Additionally, the removal volume increases by 2 times and 14 times under identical processing parameters and depths, respectively. Temperature simulations confirm that the removal sizes of resin and carbon fiber are similar under spatially shaped laser field, validating the homogeneous removal mechanism. Through the flexible design and switching of laser fields, several additional CFRP manufacturing cases has been demonstrated. This method shows significant potential for general CFRP manufacturing in various practical engineering applications.http://www.sciencedirect.com/science/article/pii/S2238785425008889Carbon fiber reinforced polymerSpatially shaped femtosecond laserLaser flexible manufacturingSelective removalHomogeneous removal |
| spellingShingle | Xueqiang Zhang Xin Li Yunduo Wang Qimeng Song Yiwen Li Kaihu Zhang Mengyao Tian Yibo Lu Xiaorui Li Sumei Wang Lan Jiang CFRP flexible manufacturing with superior quality and efficiency using a versatile spatially shaped femtosecond laser Journal of Materials Research and Technology Carbon fiber reinforced polymer Spatially shaped femtosecond laser Laser flexible manufacturing Selective removal Homogeneous removal |
| title | CFRP flexible manufacturing with superior quality and efficiency using a versatile spatially shaped femtosecond laser |
| title_full | CFRP flexible manufacturing with superior quality and efficiency using a versatile spatially shaped femtosecond laser |
| title_fullStr | CFRP flexible manufacturing with superior quality and efficiency using a versatile spatially shaped femtosecond laser |
| title_full_unstemmed | CFRP flexible manufacturing with superior quality and efficiency using a versatile spatially shaped femtosecond laser |
| title_short | CFRP flexible manufacturing with superior quality and efficiency using a versatile spatially shaped femtosecond laser |
| title_sort | cfrp flexible manufacturing with superior quality and efficiency using a versatile spatially shaped femtosecond laser |
| topic | Carbon fiber reinforced polymer Spatially shaped femtosecond laser Laser flexible manufacturing Selective removal Homogeneous removal |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425008889 |
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