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Surface structuring and functionalization of aluminium alloys using multimodal laser processing

Suhas Cholkar, Abhijit orcid logoORCID: 0000-0003-4608-3203 (2024) Surface structuring and functionalization of aluminium alloys using multimodal laser processing. PhD thesis, Dublin City University.

This thesis explores advanced multimodal laser processing techniques to fabricate nano- and micro-scale structures on aluminum alloys, targeting the marine, aerospace, and automotive industries. Aluminum alloys are known for their physical and mechanical properties but are prone to degradation from fouling, corrosion, and wear. Conventional methods for mitigating these issues are insufficient, leading to the investigation of laser-based texturing as a more robust, environmentally friendly, and scalable alternative. Chapter 2 reviews aluminum alloys as marine materials, the mechanisms of surface fouling, and traditional mitigation methods, alongside the principles of laser-based nano- and micro-fabrication techniques. Femtosecond and continuous wave (CW) fiber lasers were used to induce surface modifications that enhance antifouling, corrosion resistance, and wear performance. Chapter 3 examines ultrafast laser texturing to increase hydrophobicity in aluminum alloy 7075. By optimizing parameters such as laser power and scan speed, the water contact angle was increased from 85° to 142°, showing a highly hydrophobic surface. Environmental aging further contributed to these improvements. In Chapter 4, five laser patterns were tested for biofouling and corrosion resistance. The star pattern texture reduced biofilm coverage by 79% and improved corrosion resistance by 25%. Further, three optimized patterns were subjected to CW laser heat treatment, resulting in a 17.8% increase in microhardness and an 83% reduction in the friction coefficient. Amount of wear was reduced by 80% in the most hardened sample. Regression models were developed to fine-tune these characteristics, enhancing tribological performance. This research highlights the potential of multimodal laser processing for creating robust and ecofriendly surface modifications on aluminum alloys, significantly improving their functional properties.
Item Type:Thesis (PhD)
Date of Award:31 October 2024
Refereed:No
Supervisor(s):Brabazon, Dermot and Kinahan, David
Subjects:Engineering > Materials
Engineering > Mechanical engineering
Engineering > Production engineering
Engineering > Systems engineering
Physical Sciences > Lasers
Physical Sciences > Nanotechnology
DCU Faculties and Centres:DCU Faculties and Schools > Faculty of Engineering and Computing > School of Mechanical and Manufacturing Engineering
Research Institutes and Centres > Advanced Processing Technology Research Centre (APT)
Research Institutes and Centres > I-Form
Use License:This item is licensed under a Creative Commons Attribution-NonCommercial-No Derivative Works 4.0 License. View License
Funders:EU Horizon 2020, SFI
ID Code:30515
Deposited On:10 Mar 2025 15:13 by Dermot Brabazon . Last Modified 10 Mar 2025 15:13

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