Publications

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Pulsed laser irradiation has been used to create complex, intrinsic markings that can be used as unique identifiers for authentication and asset protection. Markings have been made on the surface of various materials by rapidly scanning a focused laser beam across a designated area as large as several square inches. Markings include macro-scale patterns, such as barcodes, that contain encrypted information. More complex markings are comprised of macro-scale patterns and embedded, unique micro-scale features. Micro-scale features form spontaneously during scanned laser irradiation and have different shapes, spacings, color and other characteristics that are virtually impossible to recreate. The macro-scale patterns can be interrogated rapidly in the field using a digital camera, while the embedded micro-scale features are best evaluated in the laboratory using microscopy or related optical techniques. Interrogated markings are compared with archived maps of the original patterns (obtained at the time of their manufacture) to determine component authenticity. The majority of experiments have involved marking planar solids. A new instrument that marks non-planar substrates is described for future work.

Nanosecond pulsed laser irradiation was used to fabricate colored, mechanically robust oxide "tags" on 304L stainless steel. Immersion in simulated seawater solution, salt fog exposure, and anodic polarization in a 3.5% NaCl solution were employed to evaluate the environmental resistance of these oxide tags. Single layer oxides outside a narrow thickness range (~100-150 nm) are susceptible to dissolution in chloride containing environments. The 304L substrates immediately beneath the oxides corrode severely-attributed to Cr-depletion in the melt zone during laser processing. For the first time, multilayered oxides were fabricated with pulsed laser irradiation in an effort to expand the protective thickness range while also increasing the variety of film colors attainable in this range. Layered films grown using a laser scan rate of 475 mm/s are more resistant to both localized and general corrosion than oxides fabricated at 550 mm/s. In the absence of pre-processing to mitigate Cr-depletion, layered films can enhance environmental stability of the system.

The rapid release of energy from reactive multilayer foils can create extreme local temperature gradients near substrate materials. In order to fully exploit the potential of these materials, a better understanding of the interaction between the substrate or filler material and the foil is needed. Specifically, this work investigates how variations in local properties within the substrate (i.e. differences between properties in constituent phases) can affect heat transport into the substrate. This can affect the microstructural evolution observed within the substrate, which may affect the final joint properties. The effect of the initial substrate microstructure on microstructural evolution within the heat-affected zone is evaluated experimentally in two Sn-Zn alloys and numerical techniques are utilized to inform the analysis.

Reactive multilayers consisting of alternating layers of Al and Pt were irradiated by single laser pulses ranging from 100 μs to 100 ms in duration, resulting in the initiation of rapid, self-propagating reactions. The threshold intensities for ignition vary with the focused laser beam diameter, bilayer thickness, and pulse length and are affected by solid state reactions and conduction of heat away from the irradiated regions. High-speed photography was used to observe ignition dynamics during irradiation and elucidate the effects of heat transfer into a multilayer foil. For an increasing laser pulse length, the ignition process transitioned from a more uniform to a less uniform temperature profile within the laser-heated zone. A more uniform temperature profile is attributed to rapid heating rates and heat localization for shorter laser pulses, and a less uniform temperature profile is due to slower heating of reactants and conduction during irradiation by longer laser pulses. Finite element simulations of laser heating using measured threshold intensities indicate that micron-scale ignition of Al/Pt occurs at low temperatures, below the melting point of both reactants.

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Reactive multilayer foils have the potential to be used as local high intensity heat sources for a variety of applications. Much of the past research effort concerning these materials have focused on understanding the structure-property relationships of the foils that govern the energy released during a reaction. To enhance the ability of researchers to more rapidly develop technologies based on reactive multilayer foils, a deeper and more predictive understanding of the relationship between the heat released from the foil and microstructural evolution in the neighboring materials is needed. This work describes the development of a numerical model for the purpose of evaluating new foil-substrate combinations for screening and optimization. The model is experimentally validated using a commercially available Ni-Al multilayer foils and different alloys.

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