Laser Manufacturing: Fit for the Future

Lead Research Organisation: The Manufacturing Technology Centre Ltd
Department Name: Research

Abstract

There is an increasing demand across engineering sectors for advanced materials, many of which are incompatible with current manufacturing processes due to their sensitivity with heat, impact and abrasion (e.g. composites, metallic glass and intermetallics). The economic machining of these materials is essential to exploit their enhanced properties and overcome some of the 21st century's challenges, including the development of efficient zero-emissions transportation.

Transportation is the largest contributor of greenhouse gas (GHG) emissions in the UK, accounting for 28% of the total. The UK Government's Transport Decarbonisation Plan aims to achieve net-zero GHG emissions by 2050, with a staged introduction from 2030. Comprehensive use of advanced composites in the structure and propulsion systems of aerospace and automotive vehicles will result in significant GHG emissions reduction. Currently, however, the lack of cost-effective and reliable manufacturing processes is limiting the pace of adoption in the aerospace and automotive industry.

This fellowship aims to develop and demonstrate next-generation laser-based manufacturing technology that will enable advanced composites to become effective solutions for application and adoption across multiple sectors. The goal will be achieved by transforming two emerging laser-based technologies into fully-fledged industrial solutions, underpinning the large scale industrialisation of advanced composite solutions.

The first of these technologies is the water-jet guided laser (WJGL); initial work performed at the MTC has proven its capability on composite cutting. However, the current generation of WJGL technology, developed for low power nanosecond lasers, is not suitable for the mass production industrial environment. To overcome this issue, this fellowship will develop a novel high-power WJGL system with a 2kW microsecond laser for cutting and drilling of composite materials, offering a 10x increase in productivity whilst maintaining component quality.

Ultra-short pulse laser (USPL) can ablate any material by cold ablation. While this extraordinary capability has been proven using low power USPL for a limited number of niche applications, its low material removal rate and its drawback of edge wall taper are currently limiting its viability in the wider manufacturing sector. To address the power limitations, the MTC together with its partners, are developing high-energy USPL with an average power of 2kW. The challenge now is to exploit the kilowatt range USPL without losing its cold ablation capability. This fellowship will develop a novel beam scanner that will facilitate stable filament-based USPL beam propagation and ultra-high-speed beam manipulation which will enable the exploitation of kilowatt range USPL for cold ablation-based machining of composites with enhanced processing rate capabilities and without edge wall taper.

Working closely with strategically vital high-value manufacturing industries, universities and the HVM Catapult centre, my fellowship aims to transform the laser-based manufacturing, manufacturability of composites, and accelerate their economic exploitation in industries, through the following:

1. Technical development: Development of novel laser-based technologies for high-volume throughput and high-quality manufacturing of composites.
2. Scientific investigation: Science-based investigations to develop the underpinning knowledge and understanding of laser-based manufacturing.
3. Industrial exploitation: Facilitate the exploitation of the laser-based composite manufacturing within the automotive and aerospace industries (both facing increased financial and environmental challenges) in the near-term and the wider manufacturing sector in the long-term.
4. Resource development: Enriching the skills base, leadership, and infrastructure for a long-term sustainable R&D competency in the UK on next-generation laser-based manufacturing.
 
Description The project has been running for around 1.5 years (out of a total of 4 years), thus it's early to discuss the extent of achieving the project objectives. The main objective and key outputs related to those objectives to date are as follows:

Technical development/scientific investigation: The technical/scientific activities are progressing in line with the core objectives. The setup for QCW laser-based waterjet guided technology has been completed and tested. The development of setup related to polygon scanner-based picosecond laser machining is in progress. A number of publications have been made on laser processing of composites and advanced materials.

Industrial exploitation: The team has been working closely with industrial project partners to enable the exploitation and transfer of technology. To date, the team has supported the exploitation of laser-based technology in two industries, namely Supercritical (on laser drilling of Hydrogen Electrolysers) and Rolls-Royce (laser drilling and machining of CMC).

Resource development: I have developed a team of approximately 10 personnel at the MTC, all working towards a shared goal. In addition to this, I have been working as a visiting lecturer at LJMU to enable the development of the next generation of engineers.
Exploitation Route 1. One of the outcome is the development of myself and my team. We will be supporting the UK research in this area of laser material processing for years to come.
2. Number of follow-on projects has been developed, through funding from industry and public funding bodies, to take the research further.
Sectors Manufacturing

including Industrial Biotechology

 
Description Its a 4 year project started in Aug 2022. Its still early to report quantifiable non-academic impact. Two major non-academic impact has been made till date; one on technology transfer to industry (Two) and another on team development (~10 personal).
First Year Of Impact 2023
Sector Aerospace, Defence and Marine,Manufacturing, including Industrial Biotechology
Impact Types Societal

Economic

 
Description 38009 - Laser Machining of CMC Components
Amount £105,676 (GBP)
Funding ID 38009 
Organisation Rolls Royce 
Sector Private
Country United States
Start 05/2022 
End 12/2022
 
Description Flexible Laser-based manufacturing through precision photon distribution (FLASH)
Amount € 5,528,497 (EUR)
Funding ID 101138380 
Organisation European Commission 
Sector Public
Country Belgium
Start 01/2024 
End 12/2026
 
Description High Speed Lamination Cutting of Electrical Steels for Laminated Stators
Amount £167,491 (GBP)
Funding ID 38404 
Organisation IPG Photonics (UK) Limited 
Sector Private
Country United Kingdom
Start 01/2023 
End 10/2023
 
Description Rolls-Royce - Laser Drilling Anti-Spatter coating v2.0
Amount £85,702 (GBP)
Funding ID 3001959 
Organisation Rolls Royce Group Plc 
Sector Private
Country United Kingdom
Start 08/2023 
End 02/2024
 
Description Water jet guided laser machining (WJGL) process optimisation for seal segment components
Amount £75,000 (GBP)
Funding ID 39078 
Organisation Rolls Royce 
Sector Private
Country United States
Start 01/2023 
End 06/2023
 
Description Wind turbine blades End of Life through Open HUBs for circular materials in sustainable business models
Amount € 12,253,714 (EUR)
Funding ID 101096425 
Organisation European Commission 
Sector Public
Country Belgium
Start 01/2023 
End 12/2026
 
Description Collaboration with the University of Birmingham 
Organisation University of Birmingham
Country United Kingdom 
Sector Academic/University 
PI Contribution The FLF project enabled to initiate collaborative work on micro-hole drilling between the UoB and the MTC. The work is still on-going.
Collaborator Contribution The UoB have got their own funding of £50k through EPSRC Impact Acceleration Account; the MTC funded £25k to support the collaborative work.
Impact Still early stage
Start Year 2023
 
Description Collaboration with the University of Nottingham 
Organisation University of Nottingham
Country United Kingdom 
Sector Academic/University 
PI Contribution The MTC has part funded a PhD studentship with the UoN to work on topic related to the fellowship. Also, we submitted a funding proposal for Royal Academy of Engineering, which was not successful.
Collaborator Contribution The PhD student has been part funded by the UoN.
Impact No major output till date; PhD work in progress
Start Year 2023
 
Description Liverpool John Moores University 
Organisation Liverpool John Moores University
Department Faculty of Engineering and Technology
Country United Kingdom 
Sector Academic/University 
PI Contribution I am currently working as a Visiting Lecturer ay LJMU, to enable collaboration, and transfer of knowledge from industry to academia, especially on training the next generation of engineers.
Collaborator Contribution Provide me the position of Visiting Lecturer;
Impact I gave lecture to ~10 MEng students. Other research work in progress.
Start Year 2023
 
Description HVMC Composite Special Purpose Group 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact A group of people from the 8 HVMC centres, discuss about the use of various technologies related to Composites Manufacturing and material Process. The group members have mandate within their organisation on the direction of the future research and capital investment.
Year(s) Of Engagement Activity 2023,2024
 
Description HVMC Laser community of practice 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact A group of people from the 8 HVMC centres come together, to discuss about the direction of the technology, collaboration, and how to influence the UK industries on the use of lasers.
Year(s) Of Engagement Activity 2024
 
Description HVMC Subtractive Special Purpose Group 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact A group of people from the 8 HVMC centres, discuss about the use of various technologies related to Subtractive Manufacturing Process. The group members have mandate within their organisation on the direction of the future research and capital investment.
Year(s) Of Engagement Activity 2022,2023,2024
 
Description Rolls-Royce Community of Practice - WJGL of CMC 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact My team member, Helen Elkington, gave a talk to at the Rolls-Royce "Laser Community of Practice" group, attended by laser users from various Rolls-Royce site across the globe. The presentation gave info on how lasers cab be used to enhance manufacturing process.
Year(s) Of Engagement Activity 2023
 
Description Yearly Laser Matters Event 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact My team member, Mitchell Leering gave a presentation on the use of laser for subtractive manufacturing process.
Year(s) Of Engagement Activity 2023