Effect of backing plate on thermal cycles in laser surface

treatment: Theoretical and Experimental study

Thesis submitted to Indian Institute of Technology Kharagpur for the award of the
degree of

Master of Technology
in
Mechanical Engineering with Specialization in
Manufacturing Science and Engineering
by

Mohit Goenka
(10ME31001)

Under the guidance of

Prof. A. K. Nath

Department of Mechanical Engineering

Department of Mechanical Engineering

Indian Institute of Technology Kharagpur
2014-2015

INDIAN INSTITUTE OF TECHNOLOGY

KHARAGPUR
CERTIFICATE
This is to certify that the thesis entitled, Effect of backing plate on thermal cycles
in laser surface treatment: Theoretical and Experimental study submitted by
Mr. Mohit Goenka (10ME31001) as a part of Master of Technology Project in
Indian Institute of Technology, Kharagpur is a bonafide work completed under my
supervision and guidance.
He has been sincere, diligent and eager to grasp more knowledge in his field of work.
I wish him good luck in his future endeavours.

Date: May 31, 2015

Prof. A.K Nath
Place: IIT Kharagpur

CERTIFICATE OF EXAMINATION

This is to certify that we have examined the thesis entitled Effect of backing plate
on thermal cycles in laser surface treatment: Theoretical and Experimental
study submitted by Mohit Goenka and hereby accord our approval of it as a work
carried out and presented in a manner required for its partial fulfillment for the degree
of Master of Technology in Manufacturing Sciences for which it has been submitted
.This approval does not necessarily endorse to or accept every statement made,
opinion expressed or conclusion as recorded in the thesis. It only signifies the
acceptance of the thesis for the purpose for which it is submitted.

External Examiner

Date:

May 2015

Place: Kharagpur

DECLARATION

I certify that

a. The work contained in this report is original and has been done by me under
the guidance of my supervisor.
b. The work has not been submitted to any other Institute for any degree or
diploma.
c. I have followed the guidelines provided by the Institute in preparing the
report.
d. I have conformed to the norms and guidelines given in the Ethical Code of
Conduct of the Institute.
e. Whenever I have used materials (data, theoretical analysis, figures, and text)
from other sources, I have given due credit to them by citing them in the text
of the report and giving their details in the references. Further, I have taken
permission from the copyright owners of the sources, whenever necessary.

Mohit Goenka

ABSTRACT
An analytical solution for the variation in thermal cycles in a finite thickness
workpiece, kept on different semi-infinite backing materials and irradiated by a
stationary and moving laser beam has been derived. The effects of laser beam
diameter, scan speed and backing material with heat sink compound in between on
thermal cycles have been investigated experimentally. The thermal cycles are
recorded using a non-contact type IR pyrometer. Mild steel, stainless steel and
aluminium are used as backing materials, considering their heat conduction capacity.
The effect of these backing materials on cooling rate, affected heat region and
solidification time are studied. The cooling trend from analytical model and
experiment has been compared. For experiment, a 1 mm finite AISI 1020 sheet has
been used and it is irradiated with a stationary laser beam for 0.9 sec for stationary
laser beam by varying spot diameters and keeping the power density constant. For
moving laser beam, sample has been irradiated with 3 mm spot diameter by varying
scan speed. The study shows that the cooling rate at surface i.e. at z=0, for a sample
decreases with increase in laser spot diameter and this trend is maintained for all the
six samples considered. Cooling is faster as the thermal conductivity of the backing
material, with heat sink compound, increases but for a same backing material, without
heat sink compound, it decreases. Cooling rate at z=0 for a finite mild steel sheet is
minimum and for semi-infinite mild steel sheet it is maximum. Solidification time or
melt pool life time follows the same trend as above, viz. for a given sample it
decreases with the decrease in spot diameter. For a given spot diameter, with increase
in thermal conductivity of backing plate it decreases. With increase in scan speed the
effect of backing plate decreases viz. for higher scan speed value of 3500 mm/min
cooling rate across all samples are nearly close by and consecutively the effect of
backing plate is not observed. For a range of ~0.7-0.75 Cr value thermal cycle plot
from analytical model is in good agreement with the experimental graphs for a
moving heat source at non-melting condition. All these have been demonstrated using
thermal cycle plots, cooling rate bar plots, and heat affected region plots generated
using experimental data.

ACKNOWLEDGEMENT

I would like to express my deep sense of gratitude and profound thanks to Prof. A.K
Nath, Department of Mechanical Engineering, IIT Kharagpur for providing me with
this wonderful opportunity to work as a part of the team under his guidance. I am
greatly thankful to him for encouraging us to come up with innovative solutions.

I am also indebted to Mr Muvvala Gopinath for patiently mentoring and helping me

out with project. I would like to credit Mr Shitanshu Shekhar Chakraborty for writing
the MATLAB programme.

Mohit Goenka
10ME31001

vi

LIST OF FIGURES
Fig. No.

Title

Page No.

3.1

Schematic representation of an infinite sheet subjected to uniform

heat flux at the top surface.

3.2

Laser irradiation on a finite sheet of thickness h unit

3.3

Schematic representation of heat partitioned at the z=0 interface

3.4

(i) Radial conduction for stationary laser beam, (ii) Radial

conduction for moving laser source beam

4.1.1

2 kW Ybfiber laser used

4.1.2

laser on time pulse for 0 sec input interaction time

10

4.1.3

laser on time pulse for 0.5 sec input interaction time

10

4.2.1

4.2.2

4.3.1
4.3.2
5.1.1

(a) Schematic representation of a stationary laser beam falling on a

semi-infinite mild steel plate for 0.9sec, (b) Schematic representation
of a stationary laser beam falling on finite mild steel sheet placed on
a backing material with heat sink compound applied
(c) Schematic representation of a stationary laser beam falling on
finite mild steel sheet for 0.9sec, (b) Schematic representation of a
stationary laser beam falling on finite mild steel sheet placed on a
backing material with no heat sink applied
(a) Power meter, model-COMET-10K-V1 ROHS OPHIR make,
accuracy 5% (b) Laser head (c) Pyrometer (d) Mild steel, AISI1020 sample placed at an angle of 450 with the vertical
Reading for laser power absorptivity for AISI-1020 at varied laser
powers
Thermal plot for top surface i.e. z-=0 for different samples on being
irradiated with a 2mm stationary laser spot diameter for 0.9sec from
Analytical Model using MatLab

12

12

13
14
15

5.1.2

Thermal plot for top surface i.e. z-=0 for different samples on being
irradiated with a 3mm stationary laser spot diameter for 0.9sec from
Analytical Model using MatLab

15

5.2.1

Experimental thermal cycle at z-=0 for samples on being irradiated

with a 4mm laser spot diameter for 0.9sec

16

5.2.2

Cooling plot for top surface i.e. z-=0 for different samples on being
irradiated with a 2mm laser spot diameter for 0.9sec using
experimental data

16

5.2.3

Cooling plot for top surface i.e. z-=0 for different samples on being
irradiated with a 3mm laser spot diameter for 0.9sec using
experimental data

17

5.2.4

Cooling plot for top surface i.e. z-=0 for different samples on being
irradiated with a 4mm laser spot diameter for 0.9sec using
experimental data

17

5.2.5

Cooling rate for samples at z = 0 on irradiation with stationary source

of different spot diameters

18

vii

5.2.6

(a) Intensity distribution for different spot radius (b) Olympus Model
SZ 1145TR PR zoom sterio microscope (c) 3X Magnification image
of affected region for 3mm spot on finite MS sheet

20

5.3.1

(a) Heat affected region on the finite mild steel sheet for different
laser spot diameter, (b) Affected region on the semi-infinite mild
steel sheet for different laser spot diameter

21

5.3.2

Plot of heat affected region on sample surface; 2mm spot diameter, P

= 300W, V=0 and t= 0.9 sec

21

5.3.3

Plot of heat affected zone on sample surface; 3mm spot diameter, P =

675W, V=0 and t= 0.9sec

22

5.3.4

Plot of heat affected zone on sample surface; 4mm spot diameter, P =

1200W, V=0 and t = 0.9 sec

22

5.4.1

Cooling curve for different samples; 3mm spot diameter, P=675W,

V=0(scan speed) and t = 0.9 sec

23

5.4.2

Cooling curve for different samples; 4mm laser spot dia, P=1200W,
V=0(scan speed) and t = 0.9sec

23

5.5.1

Cooling trend at z=0 for semi-infinite mild steel sheet with different
laser spot diameters

24

5.5.2

Cooling trend at z=0 for finite mild steel sheet with different laser
spot diameters

24

5.6.1

Thermal cycle for 1mm MS plate at varying scan speed at z = 0, P =

400W and 3 spot diameter

25

5.6.2

Thermal cycle for 1mm MS plate at varying scan speed at z = 0, P =

600W and 3 spot diameter

25

5.7.1

Cooling cycle at z = 0 for various samples with P = 600W, 3 spot

diameter and 2000mm/min scan speed as laser parameter

26

5.7.3

Cooling cycle at z = 0 for various samples with P = 600W, 3 spot

diameter and 2500mm/min scan speed as laser parameter
Cooling cycle at z = 0 for various samples with P = 600W, 3 spot
diameter and 3000mm/min scan speed as laser parameter

5.7.4

Cooling cycle at z = 0 for various samples with P = 600W, 3 spot

diameter and 3500mm/min scan speed as laser parameter

27

5.7.5

Cooling rate for samples at z = 0 on irradiation with moving heat

source of different scan speed, P = 600W and 3mm spot diameter

28

5.7.6

Cooling cycle at z = 0 for various samples with P = 400W, 3 spot

diameter and 1000mm/min scan speed as laser parameter

30

5.7.7

Cooling cycle at z = 0 for various samples with P = 400W, 3 spot

diameter and 1500mm/min scan speed as laser parameter

30

5.7.8

Cooling rate for samples at z = 0 on irradiation with moving heat

source of different scan speed, P = 400W and 3mm spot diameter

31

5.8.1

Cooling cycle at z = 0 from IR pyrometer for 1mm MS sheet, P =

400W, 3 spot diameter and varying laser scan speed

32

5.7.2

viii

26
27

5.8.2

Cooling cycle at z = 0 from Analytical model for 1mm MS sheet, P =

400W, 3 spot diameter and varying laser scan speed, Cr = 0.7

32

5.8.3

Cooling cycle at z = 0 from IR pyrometer for 1mm MS sheet, P =

600W, 3 spot diameter and varying laser scan speed

33

5.8.4

Cooling cycle at z = 0 from Analytical model for 1mm MS sheet, P =

600W, 3 spot diameter and varying laser scan speed, Cr = 0.7

33

5.8.5

Cooling cycle at z = 0 from Analytical model for 1mm MS sheet, P =

600W, 3 spot diameter and varying laser scan speed, Cr = 1

34

LIST OF TABLES
Table No.
4.2.1
4.2.2

Title
Laser parameters for stationary heat source, interaction time kept
constant at 0.9s
Laser parameters for Moving heat source, laser spot diameter
constant at 3mm

5.2

Materials used for the experiment and their properties. (source:

EES and wikipidea)
Reading for laser power absorptivity for AISI-1020 at varied laser
powers
Temperature at two fixed interval for different spot diameter

5.3

Radius of the heat affected region on the samples surface

4.2.3
4.3

5.7.1
5.7.2

Temperature at two fixed interval for a given laser scan speed, P =

600W
Temperature at two fixed interval for a given laser scan speed, P =
400W

ix

Page No.
11
11
11
14
18
20
28
31

TABLE OF CONTENTS
ABSTRACT .............................................................................................................................. v
ACKNOWLEDGEMENT...................................................................................................... vi
LIST OF FIGURES ............................................................................................................... vii
LIST OF TABLES .................................................................................................................. ix
1. INTRODUCTION................................................................................................................ 1
2. LITERATURE SURVEY .................................................................................................... 2
3. ANALYTICAL MODELLING .......................................................................................... 4
4. EXPERIMENTAL DETAILS ............................................................................................ 9

5.

4.1.

Specifications of Laser used ...................................................................................... 9

4.2.

Experiment Procedure and Laser Parameters .......................................................... 10

4.3.

Absorptivity of Mild Steel (AISI-1020): ................................................................. 13

RESULTS AND DISCUSSION .................................................................................... 15

5.1.

Thermal cycle plot from Analytical Modelling ....................................................... 15

5.2.

Cooling plots of thermal cycle by IR sensor Stationary Heat Source ................... 16

5.3.

Effect of laser spot diameters on affected region ..................................................... 20

5.4.

Effect of backing on solidification time ................................................................... 23

5.5.

Effect of laser spot diameter on solidification time ................................................. 24

5.6.

Thermal Cycle for 1mm mild steel plate Moving Heat Source ............................ 25

5.7.

Effect of backing plate on cooling rate Moving Heat Source ............................... 26

5.8.

Cr, effective radial heat conduction: Moving Heat Source ...................................... 32

6.

CONCLUSION .............................................................................................................. 35

7.

REFERENCES ............................................................................................................... 36

8.

APPENDIX ..................................................................................................................... 37

xi

1. INTRODUCTION
Modification of surface properties over multiple length scales plays an important role
in optimizing a materials performance for a given application. Lasers provide the
ability to accurately deliver large amounts of energy into confined regions of a
material in order to achieve a desired response. For opaque materials, this energy is
absorbed near the surface, modifying surface chemistry, crystal structure, and/or
multiscale morphology without altering the bulk.
Cooling rate during laser treatment plays a crucial role in material surface properties.
Cooling time for a finite mild steel sheet on irradiation with laser beam is slow as heat
gets accumulated in it. So the study of backing plate and laser spot diameter effect on
the cooling rate becomes useful to control the cooling trend. Analytical Modelling
becomes important in such case to understand the process and control it. The target
with modelling is:
i. Semi quantitative understanding of the process mechanisms for the design of
experiments and display of results dimensional analysis, order of magnitude
calculations.
ii. Parametric understanding for control purposes empirical and statistical charts,
analytic models.
iii. Detailed understanding to analyse the precise process mechanisms for the
purpose of prediction, process improvement and the pursuit of knowledge
analytic and numeric models.
The analytical model for semi-infinite composite body considers both the body to be
semi-infinite [1]. Later a partitioning function was established to take into account the
laser treatment of finite sheet kept on a semi-infinite sheet [2]. It tries to quantify the
fraction of heat flow from top body to the bottom body at the interface. Clearly it now
helps to understand the cooling trend for a finite sheet irradiation by laser beam for
parameters like spot diameter, scan speed, power, backing material etc.

2. LITERATURE SURVEY
Mathematical modelling is a tool to understanding and control of a process. There are
many research papers depicting the shear importance of this tool to analyse a process
undertaking certain assumptions. Steen and Mazumder [3] have discussed quite a few
analytical models:
i.

Analytic models in 1-d heat flow.

a. Assumption: Heat flows in 1 direction and there is no convection or heat
generation. Equation:
T(z, t) = 2Fo (t)0.5 /K ierfc{z/2(t)0.5 } ,

ii.

= thermal diffusivity, Fo = absorbed intensity, t = interaction time

Analytical models for a stationary point source.

a. The instantaneous point source

b. The continuous point source: Since heat is not a vector quantity the effects
from different heat sources can be added [4].
c. Source other than point source: By integrating point source solution over an
area it is possible to calculate the heating from line sources, disc sources or
Gaussian sources. Carslaw and Jaeger [1] discusses solutions for nearly any
geometry.
iii.

Analytical models for a moving point source: By integrating the point

solution over time and moving it by making x= (xo+vt). Rosenthal [5]
developed the well-known fundamental welding equations.

iv.

Analytical keyhole models-Line source solution: Assumed that energy is

absorbed uniformly along a line in the depth direction.

Carslaw and Jaeger [1] discussed the analytical modelling for semi-infinite
composite solid. It considers that suppose the region x>0 is of one substance, K1,
1, k1 and x<0 of another, K2, 2, k2, the boundary conditions at the plane of
separation x=0 being T1=T2, at x=0 and t>0 and K1T1/x = K2T2/x , at x=0,
t>0 where T1 is for the temperature in the region x>0, and T2 for that in the region
x<0. It discussed the solution for two conditions:

i.

The initial temperature T, constant, in x>0 and zero in x<0. Solving gave:
T2 =

ii.

K1 k1 0.5 T

z
ierfc

K1 k1 0.5 + K 2 k 2 0.5

= 2k 2 t

The initial temperature zero. Heat was supplied for t> 0 at the constant rate
Fo per unit time per unit area in the plane x=0. Solving gave:
T2 =

2Fo (k1 k 2 t)0.5

z
ierfc

K1 k 2 0.5 + K 2 k1 0.5

= 2k 2 t

Both the above analytical model was derived assuming the composite body is of semiinfinite length.
Duley [2] presented, in his book, the concept of partitioning function. The book
discusses the effect of semi-infinite body on analytical model of finite thickness
composite body; here the semi-infinite body act a base material for a finite body. It
says that when a finite body with K1, 1, k1 is kept on a semi-infinite body with
material property K2, 2 and k2, where K, and k are thermal conductivity, density
and thermal diffusivity of the respective bodies, the heat partitioned at the interface is
given by a partitioning function:
Pr =

K1 k 2 K 2 k1
K1 k 2 + K 2 k1

Cooling rate plays an important role in deciding the microstructure of the material.
The rate with which solidification occurs is equally important and controlling it by
changing various parameters can be achieved. Laser surface processing has been a
key element in a number of large-scale industrial manufacturing operations, yet at the
same time it continues to reinvent it-self and find ever new uses in emerging areas.
Matthew et al. [6] discusses some of the versatile capabilities of laser processing to
modify the surface properties of materials in order to enhance their performance for a
variety of applications.

3. ANALYTICAL MODELLING
For an infinitely thick sheet subjected to uniform heat flux at the entire top surface as
shown in Fig. 3.1 solution of temperature field can be obtained by solving the
following equation:

H
Z=0
Z

Fig 3.1. Schematic representation of an infinite sheet subjected to uniform heat flux at the top
surface.

2 T(z, t)
1 T(z, t)
=
,
z 2
K t

T|z= = T0

= H,
z z=0

T|t=0 = T0 z

(3.1)

Here, T, z, t, k, K, H and T0 denote temperature, depth from the top surface, time,
thermal diffusivity, thermal conductivity, magnitude of heat flux and initial sheet
temperature respectively. Now, a moving laser beam takes d/v time to move over a
point on its scan path where the laser beam diameter is d and v is the scans peed. If
the laser spot diameter d and the sheet thickness h are much larger than the thermal
diffusion length, given by 2kd/v corresponding to the time, d/v the sheet can be

considered to be semi-infinite and this heat transfer problem can be approximated to

be similar to the situation depicted in Fig. 1. In that case the temperature as a function
of z and t can be obtained as follows [3]:

For td/v (i.e during heating),

T = T0 +

H
z
ierfc ,
K

T = T0 +

z
H
z
ierfc ierfc ,

= 2kd/v

For td/v (i.e during cooling),

= 2k(t d/v)

(3.2)

Here, H is taken as absorbed laser power intensity at the top surface (z = 0), 4 / (d2),
A and P being absorptivity and laser power respectively. Considering semi-infinite
sheet but adding a correction term for radial heat conduction loss the solution given
by Eq.(3.2) can be modified as the following [2]:
4

For td/v (i.e during heating),

1/2

z 2 + (d2 /4)
H
z
T = T0 +
ierfc ierfc
K

For td/v (i.e during cooling),

1/2

z
H
z 2 + (d2 /4)
T = T0 + ierfc ierfc

1/2

z
z 2 + (d2 /4)
ierfc ierfc

= 2kd/v

(3.3)

= 2k(t d/v)

Considering the sheet to have finite thickness the solution of temperature field without
radial heat conduction loss can be obtained as follows [4]:
Laser beam
Z=0
Z

h
2h-Z
Fig 3.2. Laser irradiation on a finite sheet of thickness h unit

For td/v (i.e during heating),

n

|2ih z|
|2(i 1)h + z|
H
T = T0 +
ierfc
+ ierfc

i=1

For td/v (i.e during cooling),

(3.4)

|2ih z|
|2(i 1)h + z|
H
T = T0 + ierfc
+ ierfc

i=1

ierfc

|2ih z|
|2(i 1)h + z|
+ ierfc
,

= 2k(t d/v)

Here, theoretically the value of n should be infinite but practically this solution
converges rapidly with increasing value of n. Thus, combining the approaches used
for obtaining Eqs. (3.3) and (3.4) a solution of temperature for finite sheet thickness
with radial conduction loss can be arrived at as given by [7],
5

For td/v (i.e during heating),

n

1/2

|2(i 1)h + z|
H
(2(i 1)h + z)2 + (d2 /4)
T = T0 +
ierfc
ierfc

i=1

1/2

|2ih z|
(2ih z)2 + (d2 /4)
+ ierfc
ierfc

(3.5)

For td/v (i.e during cooling),

1/2

2
2
ierfc |2(i 1)h + z| ierfc (2(i 1)h + z) + (d /4) +
n

H
T = T0 +

1/2

K

(2ih z)2 + (d2 /4)
|2ih z|
i=1
ierfc

ierfc

1/2
(2(i 1)h + z)2 + (d2 /4)
|2(i 1)h + z|
ierfc
ierfc
+

1/2

(2ih z)2 + (d2 /4)

|2ih z|
ierfc

ierfc

A plate with finite thickness is kept over a substrate of semi-infinite length. (K1, k1, 1,
Cp1) and (K2, k2, 2, Cp2) denotes the thermal conductivity, thermal diffusivity, density
and specific heat capacity of the top plate and substrate respectively.
Now for material properties and scan speed such that the diffusion length > h ,
where = 2k1 d/v , h is the plate thickness, d is beam diameter and v is scan speed,

a partitioning function Pr comes into equation 5 accounting for the heat partitioned by
the substrate top surface.
For td/v (i.e during heating),
n

1/2

|2(i 1)h + z|
H
(2(i 1)h + z)2 + (d2 /4)
T = T0 +
Pr i ierfc
ierfc

K
i=0

1/2

|2ih z|
(2ih z)2 + (d2 /4)
+ ierfc
ierfc

For td/v (i.e during cooling),

(3.6)

1/2

2
2
ierfc |2(i 1)h + z| ierfc (2(i 1)h + z) + (d /4) +
n

H
T = T0 + Pr i

1/2

K

(2ih z)2 + (d2 /4)
|2ih z|
i=0
ierfc

ierfc

1/2
(2(i 1)h + z)2 + (d2 /4)
|2(i 1)h + z|
ierfc
ierfc
+

1/2

(2ih z)2 + (d2 /4)

|2ih z|
ierfc

ierfc

Where partitioning function is given as [2]:

Pr =

K1 k 2 K 2 k1
K1 k 2 + K 2 k1

During laser processing, for a stationary heat source, radial heat conduction takes
place in all direction i.e. effectiveness of radial heat conduction Cr = 1. For a moving
heat source Cr < 1 as radial heat conduction along the scan direction is negligible. So
this factor Cr was multiplied to the radial part of the equation 3.6.
For td/v (i.e during heating),
T = T0 +

1/2

|2(i 1)h + z|
H
(2(i 1)h + z)2 + (d2 /4)
Pr i ierfc
Cr ierfc

i=0

1/2

|2ih z|
(2ih z)2 + (d2 /4)
+ ierfc
Cr ierfc

(3.7)

For td/v (i.e during cooling),

T
= T0

1/2

2
2
ierfc |2(i 1)h + z| C ierfc (2(i 1)h + z) + (d /4)
r
n

H
i
+ Pr
1/2
K

(2ih z)2 + (d2 /4)
|2ih z|
i=0
ierfc

ierfc

1/2
(2(i 1)h + z)2 + (d2 /4)
|2(i 1)h + z|
ierfc
Cr ierfc
+

1/2

(2ih z)2 + (d2 /4)

|2ih z|
ierfc
Cr ierfc

Laser beam
Z=0

Finite, h mm

E1

E2
E3

K1, k1, 1, Cp1

K2, k2, 2, Cp2

Semi-infinite body

Fig 3.3. Schematic representation of heat partitioned at the z=0 interface

Here in the above figure 3.3, heat gets partitioned at the interface of the two body at Z
= 0. This partitioning is represented in the figure.
E2 = Pr E1 ,

where Pr =

K1 k 2 K 2 k1
K1 k 2 + K 2 k1
Scan Speed, V mm/min

V=0
Laser beam

ii

Fig.3.4. (i) Radial conduction for stationary laser beam, (ii) Radial conduction for moving
laser source beam

The above figure 3.4 represents the schematic for radial heat conduction in two cases,
i.e. for stationary heat source and moving heat source respectively. For stationary heat
source since heat conduction is in all the direction Cr = 1 is applied and for moving
heat source since there is no conduction along the scan speed direction Cr value has to
be less than 1.

Cr (i) = 1

Cr (ii) < Cr (i)

8

4. EXPERIMENTAL DETAILS
4.1. Specifications of Laser used
The experiments were carried out with a 2 kW Ybfiber laser (IPG photonics, Model
no. YLR - 2000) operating at 1.07 m wavelength. This can be operated in CW and
pulsed-mode in 501000 Hz frequency range with 5100% duty cycle. The laser
beam delivery system is mounted on a 5-axis CNC machine capable to move at
speeds up to 20 m/min scan speed effectively.

Fig. 4.1.1. 2 kW Ybfiber laser

The actual power of this laser is not same as the power set. This laser was capable of
providing power upto 1280 W.
During the experiments it was observed that the laser on time for 0.5 sec input on time
was more than this. A diode oscilloscope setup was used to find the machines
actual on time. It was found that the laser on time for 0 sec input laser interaction time
was 0.9 sec and for 0.5 sec input time it was ~ 1.4 sec. Below fig. 4.1.2. and fig. 4.1.3.
represents the pulse on time generated using oscilloscope. The extra 0.85 sec without
any input on time is the time taken by the machine to read the programm lines. For fig
4.1.2 each division represents 200ms and so total pulse on time is 4.5 times 200ms
which is ~ 0.9 sec. Similarliy for fig 4.1.3 each division is 197ms and so total pulse on
time is 7 times 197ms which is ~ 1.4 sec.

Fig. 4.1.2. laser on time pulse for 0 sec input interaction time

Fig. 4.1.3. laser on time pulse for 0.5 sec input interaction time

4.2. Experiment Procedure and Laser Parameters

For a stationary heat source mild steel plate of finite thickness with various backing
plates was irradiated with a staionary laser beam for 0.9sec. It was carried out to see
the affect of thermal conductivity of the backing plates on temperature behavior or the
cooling trend of the heat affected zone at Z=0 or in other words to observe the effect
of partitioing fucniton used in the anlytical model of the same. Also, the affected
region on the top surface of the mild steel due to laser irradiation gives us an idea
about radial and vertical conduction of heat for different backing plates. For this 3
different laser spot diameters were used and the laser power was changed accordingly
to maintain effective power density constant.

10

For moving heat source case similar procedure was followed with keeping spot
diameter constant at 3mm and changing the scan speed for a given power.
Table 4.2.1. Laser parameters for stationary heat source, interaction time kept constant at 0.9s

300

675

1200

Laser Spot diameter (mm)

Laser Power (W)

Table 4.2.2. Laser parameters for Moving heat source, laser spot diameter constant at 3mm

Laser Scan Speed (mm/min)

400W

1000

1500

2000

2500

3000

600W

2000

2500

3000

3500

4000

Table 4.2.3. Materials used for the experiment and their properties. (source: EES and wikipidea)

Conductivity (W/m/K) Density (Kg/m3)

Specific heat (J/kg/K)

Mild Steel (AISI-1020)

43

7850

620

Stainless Steel

16

7873

504.8

Aluminum

205

2688

936.6

Laser parameters are so selected such that the thermal diffusion length is always much
greater than the thickness of the top mild teel plate. From above thermal diffusivity of
mild steel is
k = K/Cp , 8.810-6 m2/s

= 2kt, where t interaction time is ~0.9sec. Hence, the thermal diffusion length
is 5.6mm which is much more than 1mm mild steel plate.

Mild steel with finitte thickness was kept on different material of semi-inifinite
thickness. In this experiment mild steel was irradiated with stationary laser beam for
six different samples and for each sample three laser spot diameters were used.
Inorder to improve the contact between the 2 plates, a heat sink compound was
applied in between the plates. For moving heat source the case with mild steel
backing without heat sink compound was not carried out. Below mentioned are the six
samples:
11

Mild Steel of finite

Semi-Infinite Mild Steel

Mild Steel (1mm) + Mild

thickness (1mm)

Plate

Steel backing (13mm)

Mild Steel (1mm) + Heat

Mild Steel (1mm) + Heat

Mild Steel (1mm) + Heat

Sink + Mild Steel backing

Sink + Stainless Steel

Sink + Aluminium backing

(13mm)

backing (10mm)

(12.5mm)

To avoid repetition in the paper, following short forms have been used ahead:
MS: Mild Steel; SS: Stainless Steel; Al: Aluminium; HSC/HS: Heat Sink Compound
Below schematics represent the laser irradiation on MS plate for different samples:

Z=0

Z=0

Al or SS or

(a)

(b)

Fig 4.2.1 (a) Schematic representation of a stationary laser beam falling on a semi-infinite mild steel
plate for 0.9sec, (b) Schematic representation of a stationary laser beam falling on finite mild steel
sheet placed on a backing material with heat sink compound applied

Z=0

Z=0

(c)

(d)

Fig 4.2.2. (c) Schematic representation of a stationary laser beam falling on finite mild steel sheet for
0.9sec, (b) Schematic representation of a stationary laser beam falling on finite mild steel sheet placed
on a backing material with no heat sink applied

12

Temperature was measured with the help of a non-contact infrared (IR) sensor
(Micro-Epsilon make, model no. CTLM-2HCF3-C3H, temperature range=385 C to
1600 C, response time=1ms) during the heating process of the workpiece. All the
readings of the plots generated using pyrometer is to be multiplied with a calibration
factor of 2.3. So for this experiment the minimum temperature measure was 885.5 C.

4.3. Absorptivity of Mild Steel (AISI-1020):

The absorptivity of the 1mm mild steel surface was estimated by measuring the
incident and reflected laser powers from the surface with a laser power meter (modelCOMET-10K-V1 ROHS OPHIR make, accuracy 5%). The power meter needs a
continuous laser exposure of 10 s for each measurement. The average value of
absorptivity was estimated to be ~75%. Below fig. 4.3 shows the instruments used to
find the AISI-1020 absorptivity.

a
d
c

Fig. 4.3.1. (a) Power meter, model-COMET-10K-V1 ROHS OPHIR make, accuracy 5% (b) Laser
head (c) Pyrometer (d) Mild steel, AISI-1020 sample placed at an angle of 450 with the vertical

To find absorptivity of AISI-1020 laser power was increased from 200W to 600W in
steps of 100W and resulting absorptivity value from each has been averaged.
13

Mild steel sample was kept at an angle of 45o with the vertical. For a given laser
power and 16mm laser spot diameter 3 readings T1, T2 and T3 were taken. Table 4.3
below shows the data from the experimental values obtained from the power meter.
AISI-1020 was irradiated with laser beam and the reflected laser power was captured
by the power meter.
Both the average laser power reflected and % absorptivity has been depicted through
Table 4.3 and fig 4.3.2 histogram plot below.

Table 4.3. Reading for laser power absorptivity for AISI-1020 at varied laser powers

Reflected Power (W)

Laser Power
(W)

AVG.

%
Absorptivity

T1

T2

T3

200

116.8

106.3

116.3

113.1333

43.43

300

147

121.9

136

134.97

55.01

400

98.6

95.8

102.1

98.83

75.3

500

89.2

87.3

92

89.5

82.1

600

86.4

83.2

89

86.2

85.63

100

% Absorptivity

80
60
40
20
0
200

300

400
Laser Power (W)

500

600

Fig. 4.3.2. Plots representing the laser power absorptivity for AISI-1020 for varied laser power ranging
from 200W to 600W in steps of 100W

14

5. RESULTS AND DISCUSSION

Analytical plots for Stationary heat source:
5.1. Thermal cycle plot from Analytical Modelling
Analytical Model: Temp vs Time, stationary heat source of 2mm spot diamater,
P=300W

1800
1600
1400
Temp (C)

1200
1000

Finite MS sheet

800

AL backing

600

MS backing
SS backing

400
200
0
0

0.5

1.5

Time (sec)
Fig. 5.1.1. Thermal plot for top surface viz. z-=0 for different samples on being irradiated with a 2mm
stationary laser spot diameter for 0.9sec from Analytical Model using MatLab

Temp (C)

Analytical Model: Temp vs Time, stationary heat source of 3mm spot diamater,
P=675W

2600
2400
2200
2000
1800
1600
1400
1200
1000
800
600
400
200
0

Finite MS Sheet
AL backing
MS backing
SS backing

0.5

1.5

Time (sec)
Fig. 5.1.2. Thermal plot for top surface viz. z-=0 for different samples on being irradiated with a 3mm
stationary laser spot diameter for 0.9sec from Analytical Model using MatLab

15

Experimental plots for stationary heat source:

5.2. Cooling plots of thermal cycle by IR sensor Stationary Heat Source
1000

Thermal cycle for stationary laser beam of 4mm spot diameter, P=1200W
900

Finite MS Sheet

800

Temp (C)

Semi-Infinite Sheet

700

600

500

400
1500

1000

500

2000

Time (millisec)

Fig. 5.2.1. Experimental thermal cycle at z-=0 for samples on being irradiated with a 4mm laser spot
diameter for 0.9sec

Experiment: Stationary heat source, 2mm spot diameter, P=300W

2285
2085

Temp (C)

1885
1mm MS

1685

Semi-Infinite MS
12.5mm Al backing

1485

13mm MS backing

1285

10mm SS backing
MS backing without Hsink

1085
885
0

50

100

150

200

250

Time (millisec)

Fig. 5.2.2. Cooling plot for top surface i.e. z-=0 for different samples on being irradiated with a 2mm
laser spot diameter for 0.9sec using experimental data

16

2500

Experiment: Stationary heat source, 3mm spot diameter, P=675W

2085
1885
1685
Temp (C)

1mm MS
Semi-infinite MS

1485

12.5mm Al backing
13mm MS backing

1285

10mm SS backing
MS backing without Hsink

1085
885
0

200

400
Time (millsec)

600

800

Fig. 5.2.3. Cooling plot for top surface i.e. z-=0 for different samples on being irradiated with a 3mm
laser spot diameter for 0.9sec using experimental data.

Experiment: Stationary heat source, 4mm spot diameter, P=1200W

2285
2085

Temp (C)

1885
1685

1mm MS
Semi-Infinite MS

1485

12.5mm Al backing
13mm MS backing

1285

10mm SS backing
MS backing without Hsink

1085
885
0

500

1000

1500

Time (millisec)
Fig. 5.2.4. Cooling plot for top surface i.e. z-=0 for different samples on being irradiated with a 4mm
laser spot diameter for 0.9sec using experimental data.

17

From the above cooling plots from the experimental data, cooling rate trend is plotted
to analyse the variation in the cooling rate within a sample for different laser spot
diameters and also compare the cooling rates for a same spot diameter for different
samples.
Cooling Rate of samples for different laser spot diameters at z=0
16000

Cooling Rate (C/sec)

14000
12000
10000
2mm

8000

3mm
6000

4mm

4000
2000
0
Finite MS
sheet

MS backing
without HS

SS backing

MS backing

Al backing

Semi-Infinite
MS sheet

Fig. 5.2.5. Cooling rate for samples at z = 0 on irradiation with stationary source of different spot
diameters

The above cooling rate bar graphs have been generated considering the time taken for
different sample to cool down from a particular temperature to another at z=0.
Suppose the temperature at time t1 is T1 C and at time t2 is T2 C where t2 > t1,
cooling rate is given by (T1 T2 )/(t 2 t1 ) C/sec. For our calculation below are the
T1 and T2 considered for plotting cooling rate bar graphs:

Table 5.2. Temperature at two fixed interval for different spot diameter:

Spot dia

T1, C

T2, C

2mm

1345

885.5

3mm

1345

885.5

4mm

1288

885.5

From both the plots i.e. cooling curves from experimental data fig. 5.2.2 - 5.2.4 and
18

cooling rate bar graph fig. 5.2.4, it is observed that:

1. Cooling rate, at z=0, for a sample decreases with increase in laser spot diameter
and this trend is maintained for all six samples. This may be due to the difference
in temperature gradient for varying spot diameters. The radial temperature
gradient decreases with increase in spot diameter. Now as radial conduction will
be higher for higher temperature gradient hence cooling for 2mm spot diameter
will be faster than the 3mm and 4mm spot diameters.
2. Cooling rate, at z=0, for a given spot diameter is minimum for finite mild steel
sheet, maximum for semi-infinite mild steel sheet and lies in between for rest
samples.
3. Cooling rate with Al backing, MS backing and SS backing were in decreasing
order respectively for a given spot diameter. Reason for such trend can be argued
with their respective thermal conductivity which is also in decreasing order.
4. Although theoretically cooling rate for sample with Al backing should have been
higher than that of semi-infinite mild steel sheet but experimentally it didn't
follow the trend. This shows that even the application of heat sink compound
couldn't create a proper contact between mild steel and aluminium creating
resistance.
5. Cooling rate of mild steel backing with heat sink compound at z=0 is more than
that of mild steel backing without heat sink compound because of the presence of
air gap layer in the latter. Conductivity of air is very low and hence heat gets
accumulated rather being conducted.
Decrease in cooling rate with increase in laser spot diameter can be explained through
the following reasoning:
i. It is known that the thermal conduction is higher for high temperature
gradient. Radial temperature gradient dT/dX decreases with increase in spot
diameter, hence cooling for a 2mm laser spot is faster than a 3mm laser spot
diameter and so on.
ii. = L2/ k, where is thermal diffusion time, L is thermal diffusion length and
k is thermal diffusivity. is defined as the time it takes for heat to travel over a
distance L. Following this it is clear that energy travel in 2mm spot diameter is
faster than 3mm and so on.
19

r1=2mm
r2=3mm

r2
Spot dia 3mm, Finite
MS sheet
, 3X Magnification

r1

a
b
Fig. 5.2.6. (a) Intensity distribution for different spot radius (b) Olympus Model SZ 1145TR PR zoom
sterio microscope (c) 3X Magnification image of affected region for 3mm spot on finite MS sheet

5.3. Effect of laser spot diameters on affected region

To have a better understanding of radial heat conduction vs heat conduction along the
depth considering variation in laser spot diameters and 0.9 sec interaction time,
circular plots of the affected region is generated for different samples.
Fig. 5.3.1 shows the samples which are irradiated with a stationary laser beam varying
the spot diameter as 2mm, 3mm and 4mm respectively keeping the power density
constant. The above fig.5.2.6 (b) and (c) represents the images of those affected
region on the material surface taken using a high resolution optical microscope. To
plot the schematic of affected region, the images from optical microscope was
measured using software ImageJ.

Table 5.3. Radius of the heat affected zone on the samples surface:
Radius of the affected region for different Laser spot diameters (mm)

Samples

For 2mm spot

2.718

For 3mm spot

3.875

For 4mm spot

5.264

MS backing without HS

2.651

3.655

4.394

SS backing

2.412

3.271

4.349

MS backing

2.257

3.169

4.224

Al backing

1.818

3.073

4.043

Semi-Infinite MS sheet

1.526

2.306

3.132

Finite MS sheet

The above table 5.3 shows radius of the affected region on the sample surface for
different laser spot diameter. All the measurements are in mm.
20

3mm

4mm

2mm
(a)

(b)

Fig. 5.3.1. (a) Heat affected region on the finite mild steel sheet for different laser spot diameter, (b)
Affected region on the semi-infinite mild steel sheet for different laser spot diameter
1mm M S

2.5

Bulk M S
AL backing
M S backing
SS backing

2mm spot dia

M S without HS

1.5

mm

0.5

0.5

-1

1.5

-2

2.5

-3

-2

-1

mm

Fig. 5.3.2. Plot of heat affected region on sample surface; 2mm spot diameter, P = 300W, V=0 and t=
0.9 sec, laser interaction time

For all the three cases with different laser power and spot diameters such that the laser
power intensity remains to be a constant, in MS plate with backing condition with
heat sink the affected region radius increases as the thermal conductivity of the
backing plate decreases. For finite MS sheet the radius is maximum as in this case
radial heat conduction is maximum and heat gets accumulated. Comparing affected
region for MS backing with and without heat sink, the backing condition with heat
sink compound has smaller affected region as the heat sink compound creates a better
contact improving the thermal conduction along the depth as compared to the other
situation.

21

1mm M S
Bulk M S
AL backing

3mm spot dia

M S backing

SS backing
M S without HS

mm

-1

-2

-3

-4
-4

-3

-1

-2

mm
Fig. 5.3.3. Plot of heat affected zone on sample surface; 3mm spot diameter, P = 675W, V=0 and t=
0.9sec, laser interaction time
1mm M S

Bulk M S
AL backing
M S backing
SS backing
M S without HS

4mm spot dia

mm

-1

-2

-3

-4

-5
-6

-4

-2

mm

Fig. 5.3.4. Plot of heat affected zone on sample surface; 4mm spot diameter, P = 1200W, V=0 and t =
0.9 sec, laser interaction time

22

5.4. Effect of backing on solidification time

Cooling curve for staitionary heat source of 3mm spot diameter
2085
1885

Temp (C)

1685

Finite MS sheet
MS backing without HS

1485

10mm SS backing
13mm MS backing
12.5mm Al backing

1285

Semi-Infinte MS

1085
885
0

200

400

600
800
Time (millisec)

1000

1200

Fig. 5.4.1. Cooling curve for different samples; 3mm spot diameter, P=675W, V=0(scan speed) and t =
0.9 sec, laser interaction time

Cooling curve for staitionary heat source of 4mm spot diameter

2285
2085

Temp (C)

1885

Finite MS sheet
MS backing without HS

1685

10mm SS backing
13mm MS backing

1485

12.5mm Al backing

1285

Semi-Infinte MS

1085
885
0

400

800
1200
Time (millisec)

1600

2000

Fig. 5.4.2. Cooling curve for different samples; 4mm laser spot dia, P=1200W, V=0(scan speed) and t
= 0.9sec laser interaction time

In Fig. 5.4.1 and 5.4.2 the duration of horizontal trend during cooling or the duration
between the changes in slopes depict the solidification time.
23

5.5. Effect of laser spot diameter on solidification time

Cooling curve for stationary heat source on 1mm mild steel plate
2285
2085

Temp (C)

1885
1685
2mm Spot Dia

1485

3mm Spot Dia

4mm Spot Dia

1285
1085
885
0

200

400

600
800
Time (millisec)

1000

1200

Fig. 5.5.1. Cooling trend at z=0 for finite mild steel sheet with different laser spot diameters

Cooling curve for stationary heat source on a semi-infinite MS plate

2085
1885

Temp (C)

1685
1485

2mm Spot Dia

3mm Spot Dia

1285

4mm Spot Dia

1085
885
0

50

100
150
Time (millisec)

200

250

Fig. 5.5.2. Cooling trend at z=0 for semi-infinite mild steel sheet with different laser spot diameters

In fig. 5.5.1 and 5.5.2 it can be observed that the solidification time increases with
increase in spot diameter because the cooling rate decreases with spot diameter
increment.
24

5.6. Thermal Cycle for 1mm mild steel plate Moving Heat Source

Experimental plots for Moving heat source:

Thermal cycle for 1mm MS plate, P=400W, 3mm spot diameter
2085
1885

Temp (C)

1685
1000 mm/min
1500 mm/min

1485

2000 mm/min
1285

2500 mm/min
3000 mm/min

1085
885
0

100

200

300
400
Time (millisec)

500

600

Fig. 5.6.1. Thermal cycle for 1mm MS plate at varying scan speed at z = 0, P = 400W and 3 spot
diameter

Thermal cycle for 1mm MS plate, P=600W, 3mm spot diameter

2085
1885

Temp (C)

1685
2000 mm/min
2500 mm/min

1485

3000 mm/min
1285

3500 mm/min
4000 mm/min

1085
885
0

50

100
150
Time (millisec)

200

250

Fig. 5.6.2. Thermal cycle for 1mm MS plate at varying scan speed at z = 0, P = 600W and 3 spot
diameter

25

5.7. Effect of backing plate on cooling rate Moving Heat Source

Cooling plots for moving heat source, P = 600W, 3mm spot diameter:

P = 600W, V = 2000mm/min and 3mm spot diameter

1785
1685
1585
Temp (C)

1485
1mm MS

1385

Al backing with HS

1285

MS backing with HS

1185

SS backing with HS

1085

Bulk MS

985
885
0

50

100
Time (millisec)

150

200

Fig. 5.7.1. Cooling cycle at z = 0 for various samples with P = 600W, 3 spot diameter and
2000mm/min scan speed as laser parameter

P = 600W, V = 2500mm/min and 3mm spot diameter

2085
1885

Temp (C)

1685
1mm MS

1485

Al backing with HS
MS backing with HS

1285

SS backing with HS
Bulk MS

1085
885
0

20

40
60
Time (millisec)

80

100

Fig. 5.7.2. Cooling cycle at z = 0 for various samples with P = 600W, 3 spot diameter and
2500mm/min scan speed as laser parameter

26

P = 600W, V = 3000mm/min and 3mm spot diameter

1885
1785
1685

Temp (C)

1585
1485

1mm MS

1385

Al backing with HS

1285

MS backing with HS

1185

SS backing with HS
Bulk MS

1085
985
885
0

10

20
30
Time (millisec)

40

Fig. 5.7.3. Cooling cycle at z = 0 for various samples with P = 600W, 3 spot diameter and
3000mm/min scan speed as laser parameter

P = 600W, V = 3500mm/min and 3mm spot diameter

1685
1585

Temp (C)

1485
1385

1mm MS

1285

Al backing with HS
MS backing with HS

1185

SS backing with HS

1085

Bulk MS

985
885
0

10

20
Time (millisec)

30

40

Fig. 5.7.4. Cooling cycle at z = 0 for various samples with P = 600W, 3 spot diameter and
3500mm/min scan speed as laser parameter

27

From the above cooling plots from the experimental data, cooling rate trend is plotted
to analyse the variation in the cooling rate within a sample for different laser scan
speed and also compare the effect on cooling rates for a same scan speed for different
samples.
2000 mm/min

2500 mm/min

3000 mm/min

3500 mm/min

30000

Cooling Rate (C/sec)

25000
20000
15000
10000
5000
0
1mm Sheet

SS backing with MS backing with Al backing with

HS
HS
HS

Bulk MS

Fig. 5.7.5. Cooling rate for samples at z = 0 on irradiation with moving heat source of different scan
speed, P = 600W and 3mm spot diameter

The above cooling rate bar graphs have been generated considering the time taken for
different sample to cool down from a particular temperature to another at z=0.
Suppose the temperature at time t1 is T1 C and at time t2 is T2 C where t2 > t1,
cooling rate is given by (T1 T2 )/(t 2 t1 ) C/sec. For our calculation below are the
T1 and T2 considered for plotting cooling rate bar graphs:

Table 5.7.1. Temperature at two fixed interval for a given laser scan speed, P = 600W:

Scan Speed(mm/min)

T1, C

T2, C

2000

1480

885.5

2500

1400

885.5

3000

1500

885.5

3500

1400

885.5

28

While plotting the above cooling rate histogram plots, for a given scan speed, T1 C
and T2 C temperature during the cooling cycle chosen was same across all the
samples so as to compare the cooling rates.
Observation:
i.

For a given laser scan speed cooling rate is least for 1mm mild steel sheet, it
is maximum for bulk mild steel sheet and it ranges in between these two
extremes for the backing conditions. Cooling rate for a given scan speed
increases with the increase in thermal conductivity of the backing plate.
Reasoning for this observation remains same as discussed earlier in the case
of samples irradiation by a stationary heat source.

ii.

With the increase in laser scan speed the effect of backing plate decreases
i.e. for higher scan speed value of 3500 mm/min the cooling rate across all
samples are nearly close by and consecutively the effect of backing plate is
not observed. This may be because with the increase in scan speed laser
interaction time decreases and hence the thermal diffusion length also
decreases. Due to this for higher scan speed, as for above case, thermal
effect due to laser barely reaches the interface. As mentioned above the
thickness of mild steel sheet is 1mm. Now considering the above scan
speeds value, the theoretical thermal diffusion length = 2kd/v are:
a) For 3500 mm/min, ~1.3mm

b) For 3000 mm/min, ~ 1.45mm

c) For 2500 mm/min, ~ 1.6mm

d) & For 2000 mm/min, ~ 1.8mm

Clearly for 2000mm/min, ~ 1.8mm is greater than the mild steel sheet

thickness of 1mm as compared to laser scan speed of 3500 mm/min for

which it is closer to the mild steel sheet thickness.
iii.

For a given sample with increase in laser scan speed cooling rate increases.

29

Cooling plots for moving heat source, P = 400W, 3mm spot diameter
P = 400W, 3mm spot diameter and V = 1000 mm/min
1885
1785
1685

Temp (C)

1585
1485

1mm MS

1385

Al backing with HS

1285

MS backing with HS
SS backing with HS

1185

Bulk MS

1085
985
885
0

100

200
Time (millisec)

300

400

Fig. 5.7.6. Cooling cycle at z = 0 for various samples with P = 400W, 3 spot diameter and
1000mm/min scan speed as laser parameter

P = 400W, 3mm spot diameter and V = 1500 mm/min

2085
1885

Temp (C)

1685
1mm MS

1485

Al backing with HS
MS backing with HS

1285

SS backing with HS
Bulk MS

1085
885
0

10

20

30

40

50 60 70 80
Time (millisec)

90 100 110 120 130

Fig. 5.7.7. Cooling cycle at z = 0 for various samples with P = 400W, 3 spot diameter and
1500mm/min scan speed as laser parameter

For both 600W and 400W cooling curves for varying scan speed at constant spot
diameter the cooling rate trend is in match with the trend observed for stationary heat

30

source i.e. with the increase in backing plate thermal conductivity cooling rate also
increases.
From the above cooling plots from the experimental data, cooling rate trend is plotted
to analyse the variation in the cooling rate within a sample for different laser scan
speed and also compare the effect on cooling rates for a same scan speed for different
samples.
Cooling Rate of samples for different laser Laser scan speed, P = 400W
12000
9922.81

Cooling Rate (C/sec)

10000

8162.54
7275.26
6930.25

8000
5825.94

6000

SS backing with HS

4783.64
3863.11

4000
2000

5873.13

1mm Sheet

MS backing with HS
Al backing with HS
Bulk MS

2227.71
1931.42

0
1000 mm/min

1500 mm/min

Fig. 5.7.8. Cooling rate for samples at z = 0 on irradiation with moving heat source of different scan
speed, P = 400W and 3mm spot diameter

The above cooling rate bar graphs have been generated considering the time taken for
different sample to cool down from a particular temperature to another at z=0.
Suppose the temperature at time t1 is T1 C and at time t2 is T2 C where t2 > t1,
cooling rate is given by (T1 T2 )/(t 2 t1 ) C/sec. For our calculation below are the
T1 and T2 considered for plotting cooling rate bar graphs:

Table 5.7.2. Temperature at two fixed interval for a given laser scan speed, P = 400W:

Scan Speed(mm/min)

T1, C

T2, C

1000

1500

885.5

1500

1450

885.5

31

5.8. Cr, effective radial heat conduction: Moving Heat Source

Experimenatal: P=400 W and 3mm spot diameter

1335
1285
1235

Temp (C)

1185
1135
2000 mm/min

1085

2500 mm/min
1035
985
935
885
0

20

40
60
Time (millsec)

80

100

Fig. 5.8.1. Cooling cycle at z = 0 from IR pyrometer for 1mm MS sheet, P = 400W, 3 spot diameter
and varying laser scan speed

Analytical: P=400 W and 3mm spot diameter, Cr = 0.7

1335
1285
1235
Temp (C)

1185
1135

2500 mm/min

1085

2000 mm/min

1035
985
935
885
0

20

40
60
Time (millisec)

80

100

Fig. 5.8.2. Cooling cycle at z = 0 from Analytical model for 1mm MS sheet, P = 400W, 3 spot diameter
and varying laser scan speed, Cr = 0.7

32

Experimental: P=600 W and 3mm spot diameter

1685
1585

Temp (C)

1485
1385
3500 mm/min

1285

4000 mm/min
1185

4500 mm/min

1085
985
885
0

20

40
Time (millisec)

60

80

Fig. 5.8.3. Cooling cycle at z = 0 from IR pyrometer for 1mm MS sheet, P = 600W, 3 spot diameter
and varying laser scan speed

Analytical: P=600 W and 3mm spot diameter, Cr = 0.7

1685
1585

Temp (C)

1485
1385
3500 mm/min

1285

4000 mm/min
1185

4500 mm/min

1085
985
885
0

20

40
Time (millisec)

60

80

Fig. 5.8.4. Cooling cycle at z = 0 from Analytical model for 1mm MS sheet, P = 600W, 3 spot diameter
and varying laser scan speed, Cr = 0.7

33

Analytical: P=600 W and 3mm spot diameter, Cr = 1

1685
1585

Temp (C)

1485
1385
3500 mm/min

1285

4000 mm/min

1185

4500 mm/min
1085
985
885
0

20

40
Time (millisec)

60

80

Fig. 5.8.5. Cooling cycle at z = 0 from Analytical model for 1mm MS sheet, P = 600W, 3 spot diameter
and varying laser scan speed, Cr = 1

At 400W and 600W thermal cycle plots from both experimental and analytical
modelling has been generated as shown in above fig 5.8.1 5.8.5. Laser spot diameter
was kept at 3mm and the laser scan speed was varied for a given laser power such that
the melting case do not occur. The analytical model developed earlier is based on non
melting condition. To get a match for the thermal cycle with the experimental plot,
parameters are such chosen so as to avoid melting. By keeping the laser absorptivity
for AISI 1020 at ~75% and changing the Cr value manually, thermal cycle plot was
generated using MatLab programming.
The value for Cr was manually fed from 0.5 1.
Observation:
i. It was observed that for a range of ~0.7-0.75 Cr value and keeping all other
parameters same, the thermal cycle plot from analytical model is in good
agreement with the experimental graphs.
ii. It is clearly seen from fig 5.8.5 that the Cr = 1 incorporation to the analytical

model under predicts and is not in good agreement with the experimental
results observed in fig 5.8.3.

34

CONCLUSION

1. Cooling rate, at z=0, for a sample decreases with increase in laser spot
diameter and this trend is maintained for all the six samples considered.
2. Cooling is faster as the thermal conductivity of the backing material, with heat
sink compound, increases but for a same backing material, without heat sink
compound, it decreases.
3. Solidification time follows the same trend as above, viz. for a given sample it
decreases with the decrease in spot diameter. For a given spot diameter, with
increase in thermal conductivity of backing plate it decreases.
4. Heat affected region for a given spot diameter decreases with increase in the
conductivity of the backing plate with heat sink compound. It is maximum for
finite MS sheet and minimum for semi-infinite MS sheet in the considered
sample range.
5. For a given laser scan speed cooling rate is least for 1mm mild steel sheet, it is
maximum for bulk mild steel sheet and it ranges in between these two
extremes for the backing conditions. Cooling rate for a given scan speed
increases with the increase in thermal conductivity of the backing plate.
6. With the increase in laser scan speed the effect of backing plate decreases viz.
for higher scan speed value of 3500 mm/min cooling rate across all samples
are nearly close by and consecutively the effect of backing plate is not
observed.
7. For a range of ~0.7-0.75 Cr value thermal cycle plot from analytical model is
in good agreement with the experimental graphs for a moving heat source at
non-melting condition.

35

6. REFERENCES

[1] Carslaw.H.S., Jaeger.J.C. "Conduction of Heat in Solids" 2nd Edition Oxford

University Press, 1959.
[2] Duley, W.W., 1983. Laser Processing and Analysis of Materials. Plenum
Press, NewYork/London.
[3] Steen, W.M., Mazumder, J., 2010. Laser Material Processing, 4th ed.
Springer, London,pp. 256258.
[4] McBride, R., Bardin, F., Gross, M., Hand, D.P., Jones, J.D.C., Moore, A.J.,
2005. Modelling and calibration of bending strains for iterative laser forming.
J. Appl. Phys. D:Appl. Phys. 38, 40274036.
[5] Rosenthal. D. Trans ASME 849-866 1946.
[6] Matthew S. Brown, Craig B. Arnold Fundamentals of Laser-Material
Interaction and Application to Multiscale Surface Modification, 2010. 91120.
[7] Shitanshu Shekhar Chakraborty, Harshit More, Vikranth Racherla, Ashish
Kumar Nath, Modification of bent angle of mechanically formed stainless
steel sheets by laser forming, Journal of Materials Processing Technology,
Volume 222, August 2015, Pages 128-141, ISSN 0924-0136.

36

7. APPENDIX
Matlab code for the Analytical Model:
% Function to compute temperature vs time at Z = 0.
% Analytical model used to compute temperature evolution in a finite
% thickness sheet,
% with a sheet at the bottom attached, subjected to a stationary heat
source of constant width (equal to beam diameter) and
% and uniform intensity of magnitude 4AP/(pid^2) for time d/v
(McBride et al., 2006)
% INPUT PARAMETER
%
% A --> Absorptivity
% d --> Diameter of laser beam in mm
% P --> Laser power in W
% v --> Scan speed in m/min
% h --> Sheet thickness in mm
% zVec --> Vector containing distances from top surface in mm where
the temperature is to be estimated. First point should be z=0
% T0 --> Initial sheet temperature
% n --> No. of reflections considered in the analytical expression
for estimation of temperature in a finite thickness sheet
% TotalTime --> Total time of analyses in seconds
% TimeIncrement --> Time Increment to be used in the analyses
% TempRiseForStepCalc --> Temperature rise for the StepTime
calculation
% Cr --> Effectiveness of Radial heat conduction, < or = 1
% pr1 --> heat flow partitioning into substrate-1 kept on a base
material-2
clear all
A = 0.75; d = 3; P = 400.0; v = 1; h=1; zVec=0:0.05:1; n=50;
Cr = 0.7;
T0 = 27; TimeIncrement= (pi*d*60)/(4*v*1000*80); TotalTime=2;
TempRiseWithinTimeIncrement=10;
IntensityMultiFactor = 1; Tmeanguess=500; TPropMax1 = 1200;
k2 = 205; rho2 = 2688; cp2 = 936.6;
% k2, rho2 and cp2 are conductivity, density and specific heat of the
% bottom material in SI unit
q = IntensityMultiFactor*(A*P*1e6)/(pi*d^2/4); %Average intensity in
W/m^2
zVec = zVec/1000; %Depth in m
h = h/1000; %Sheet thickness in m
d = d/1000; %Beam diameter in m
v = v/60;
%Beam velocity in m/s
Tcond1 = [0;100;200;300;400;500;600;700;800;1000;1200]; %Temperatures
at which conductivity is specified
cond1 = [51.9;50.7;48.2;45.6;41.9;38.1;33.9;31.1;24.7;26.8;29.7];
%Conductivity at specified temperatures
Tdens1 = [0;100;200;300;400;500;600;700;800;1000;1200]; %Temperatures
at which density is specified
dens1 =
[7700;7700;7700;7700;7700;7700;7700;7700;7700;7700;7700];%Density at
specified temperatures
Tspht1 = [0;100;200;300;400;500;600;700;800;1000;1200];%Temperatures
at which specific heat is specified

37

spht1 = [486;486;550;548;586;649;708;770;624;548;548]; %Specific heat

at specified temperatures
tp = d/v; %Heating time in seconds
zLength=length(zVec);
%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%% ANALYSES FOR THE TOP
SURFACE %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%
z=zVec(1);
count=1; Temp(1,:)=[0,T0]; %Initializing count and Temperature
T(1,1)=0;
T(1,2:(n+1))=T0;
k=cond1(1);
rho=dens1(1);
c=spht1(1);
diffuse=k/(rho*c);
del=2*sqrt(diffuse*tp);
TRise1=q*del/(k*sqrt(pi));
Tmean =(T0+TRise1)/2;
if (TRise1>TPropMax1)
Tmean=TPropMax1;
end
k1 = spline(Tcond1,cond1,Tmean); %Thermal conductivity in W/m/K at
Tmean
rho1 = spline(Tdens1,dens1,Tmean); %Density in kg/m^3 at Tmean
cp1 = spline(Tspht1,spht1,Tmean); %Specific heat in J/kg/K at Tmean
diffusivity1 = k1/(rho1*cp1); %Diffusivity in m^2/sec at Tmean
diffusivity2 = k2/(rho2*cp2);
pr1=((k1/sqrt(diffusivity1))(k2/sqrt(diffusivity2)))/((k1/sqrt(diffusivity1))+(k2/sqrt(diffusivit
y2)));
pr1=1; %For without backing condition
for t = TimeIncrement:TimeIncrement:TotalTime
count=count+1;
if t <= tp %Below is the temperature estimation for the heating
period
DiffusionLength1=2*sqrt(diffusivity1*t);
DiffusionLength2=2*sqrt(diffusivity2*t);
TempRisez=0;
for i=1:n
x1
x2
x3
x4

=
=
=
=

(2*i*h+z)/DiffusionLength1;
(2*i*h-z)/DiffusionLength1;
sqrt((2*i*h+z)^2+d^2/4)/DiffusionLength1;
sqrt((2*i*h-z)^2+d^2/4)/DiffusionLength1;

f1 = 1/exp(x1^2)/sqrt(pi)-x1*(1-erf(x1));
f2 = 1/exp(x2^2)/sqrt(pi)-x2*(1-erf(x2));

38

f3 = 1/exp(x3^2)/sqrt(pi)-x3*(1-erf(x3));
f4 = 1/exp(x4^2)/sqrt(pi)-x4*(1-erf(x4));
f3=Cr*f3;
f4=Cr*f4;
TempRisez=TempRisez+q*DiffusionLength1*(pr1^i)*(f1+f2-f3f4)/k1;%Temperature rise at depth z taking n reflections with radial
heat loss
T(count,i+1) = TempRisez+T0; %Temperature estimated at z
taking i reflections
end
x1 = z/DiffusionLength1;
x3 = sqrt(z^2+d^2/4)/DiffusionLength1;
f1 = 1/exp(x1^2)/sqrt(pi)-x1*(1-erf(x1));
f3 = 1/exp(x3^2)/sqrt(pi)-x3*(1-erf(x3));
f3=Cr*f3;
TempRisez1 = q*DiffusionLength1*(f1-f3)/k1;
Temp(count,1)=t;
Temp(count,2)=T0+TempRisez+TempRisez1;

else %Below is the temperature estimation for the cooling period

DiffusionLength1=2*sqrt(diffusivity1*t);
DiffusionLength2=2*sqrt(diffusivity2*t);
DiffusionLengthCooling1 = 2*sqrt(diffusivity1*(t-tp));
DiffusionLengthCooling2 = 2*sqrt(diffusivity2*(t-tp));
sum1=0;
sum2=0;
for i=1:n
x1 = (2*i*h+z)/DiffusionLength1;
x2 = (2*i*h-z)/DiffusionLength1;
x3 = sqrt((2*i*h+z)^2+d^2/4)/DiffusionLength1;
x4 = sqrt((2*i*h-z)^2+d^2/4)/DiffusionLength1;
f1 = 1/exp(x1^2)/sqrt(pi)-x1*(1-erf(x1));
f2 = 1/exp(x2^2)/sqrt(pi)-x2*(1-erf(x2));
f3 = 1/exp(x3^2)/sqrt(pi)-x3*(1-erf(x3));
f4 = 1/exp(x4^2)/sqrt(pi)-x4*(1-erf(x4));
f3=Cr*f3;
f4=Cr*f4;
sum1 = sum1+q*DiffusionLength1*(pr1^i)*(f1+f2-f3-f4)/k1;
x11
x22
x33
x44

=
=
=
=

(2*i*h+z)/DiffusionLengthCooling1;
(2*i*h-z)/DiffusionLengthCooling1;
sqrt((2*i*h+z)^2+d^2/4)/DiffusionLengthCooling1;
sqrt((2*i*h-z)^2+d^2/4)/DiffusionLengthCooling1;

f11
f22
f33
f44

=
=
=
=

1/exp(x11^2)/sqrt(pi)-x11*(1-erf(x11));
1/exp(x22^2)/sqrt(pi)-x22*(1-erf(x22));
1/exp(x33^2)/sqrt(pi)-x33*(1-erf(x33));
1/exp(x44^2)/sqrt(pi)-x44*(1-erf(x44));

f33=Cr*f33;

39

f44=Cr*f44;
sum2 = sum2+q*DiffusionLengthCooling1*(pr1^i)*(f11+f22f33-f44)/k1;
T(count,i+1) = sum1-sum2+T0; %Temperature estimated at z
taking i reflections
end
TempRisez= sum1-sum2;
x1 = z/DiffusionLength1;
x3 = sqrt(z^2+d^2/4)/DiffusionLength1;
x11 = z/DiffusionLengthCooling1;
x33 = sqrt(z^2+d^2/4)/DiffusionLengthCooling1;
f1 = 1/exp(x1^2)/sqrt(pi)-x1*(1-erf(x1));
f3 = 1/exp(x3^2)/sqrt(pi)-x3*(1-erf(x3));
f11 = 1/exp(x11^2)/sqrt(pi)-x11*(1-erf(x11));
f33 = 1/exp(x33^2)/sqrt(pi)-x33*(1-erf(x33));
f3=Cr*f3;
f33=Cr*f33;
sum1 = q*DiffusionLength1*(f1-f3)/k1;
sum2 = q*DiffusionLengthCooling1*(f11-f33)/k1;
TempRisez1= sum1-sum2;
Temp(count,1)=t;
Temp(count,2)=T0+TempRisez+TempRisez1;
end
end
countMax=count;
TMax=max(Temp(:,2)); %Maximum temperature
p = 1; TPrevious=T0;
Results(1,1)=0; Results(1,2:(zLength+1))=T0;
for i=1:countMax
if (( abs( Temp(i,2) - TPrevious) >=
TempRiseWithinTimeIncrement)||( Temp(i,2)==TMax))
p=p+1;
Results(p,1)=i*TimeIncrement;
Results(p,2)=Temp(i,2);
TPrevious=Temp(i,2);
end
end
p=p+1;
Results(p,1)=countMax*TimeIncrement;
Results(p,2)=Temp(countMax,2); pMax=p;
delTmax = max(abs(diff(Temp(:,2))));
FigName=sprintf('TemperaturesData.emf');
h=figure;
plot(Results(:,1), Results(:,2),'LineWidth',2);
xlabel('Time (s)'); ylabel('Temperature (Deg C)');
title('Temperatures vs time');
print(h,FigName);
fclose(fid);

40