Skip to main content
SpringerLink
Log in

Influence of parameters on performance characteristics and defects during laser microdrilling of titanium alloys using RSM

  • Original Article
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Titanium (Ti) and its alloys have received significant attention recently, particularly for medical science, automobile, and aerospace applications. Drilling is used for around 40% to 60% of the material removal processes of an aeronautical product. Non-conventional machining can obtain an optimal quality of drilled holes. The present study has employed a pulsed Nd:YAG laser having 250 W average power to perform the microdrilling on a titanium alloy of 0.45-mm-thick sheet. The study focuses on determining the impact of laser parameters (gas pressure (4 ~ 8 bar), laser input current (200 ~ 260 A), pulse width (4 ~ 8 ms), and pulse repetition rate (1 ~ 7 Hz)) on performance characteristics during microdrilling on a thin foil of titanium alloy having 0.45 mm thickness. To evaluate the quality of microdrilled holes, aspects, e.g., circularity, spatter area, and taper, have been considered. The response surface methodology (RSM) based on the design of the experiment technique was employed to estimate the influence of parameters on performance characteristics with the least number of experiments. The study indicates that assistant gas pressure, pulse width, and laser input current are the essential parameters in taper formation and spatter deposition. The study suggests that the increase in pulse repetition rate and pulse width improves the circularity of the hole. The electron micrography of the drilled holes helps to determine the development of the heat-affected zone (HAZ) and microcracks near drilled holes. The presented research provides a new understanding of how the process parameters contribute to the HAZ development, crack occurrence and intensity.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20

Similar content being viewed by others

References

  1. Zhang S, Elsayed M, Peng R, Chen Y, Zhang Y, Peng J, Li W, Chamberlain MD, Nikitina A, Yu S, Liu X (2021) Reconfigurable multi-component micromachines driven by optoelectronic tweezers. Nat Commun 12(1):1–9

    Google Scholar 

  2. Garcia L, Kerns G, O’Reilley K, Okesanjo O, Lozano J, Narendran J, Broeking C, Ma X, Thompson H, Njapa NP, Sikligar D (2022) The role of soft robotic micromachines in the future of medical devices and personalized medicine. Micromachines 13(1):28

    Article  Google Scholar 

  3. Mishra S, Yadava V (2013) Modeling and optimization of laser beam percussion drilling of thin aluminum sheet. Opt Laser Technol 48:461–474

    Article  Google Scholar 

  4. Meijer J (2004) Laser beam machining (LBM), state of the art and new opportunities. J Mater Process Technol 149(1–3):2–17

    Article  Google Scholar 

  5. Konari PR, Clayton YD, Vaughan MB, Khandaker M, Hossan MR (2021) Experimental analysis of laser micromachining of microchannels in common microfluidic substrates. Micromachines 12(2):138

    Article  Google Scholar 

  6. Dubey AK, Yadava V (2008) Laser beam machining-a review. Int J Mach Tools Manuf 48(6):609–628

    Article  Google Scholar 

  7. Li W, Zhang G, Huang Y, Rong Y (2021) UV laser high-quality drilling of CFRP plate with a new interlaced scanning mode. Compos Struct 273:114258

    Article  Google Scholar 

  8. Li W, Zhang G, Chen L, Huang Y, Rong Y, Gao Z (2021) Dimethicone-aided laser cutting of solar rolled glass. Front Mech Eng 16(1):111–121

    Article  Google Scholar 

  9. Zhu Z, Sui S, Sun J, Li J, Li Y (2017) Investigation on performance characteristics in drilling of Ti6Al4V alloy. Int J Adv Manuf Technol 93(1):651–660

    Article  Google Scholar 

  10. Varkey AP, Kuriakose S, Unni VN (2014) Optimization of edge quality during CO2 laser cutting of titanium alloy. Optimization 1(11):2349–2163

    Google Scholar 

  11. Yaşar N, Korkmaz ME, Gupta MK, Boy M, Günay M (2021) A novel method for improving drilling performance of CFRP/Ti6AL4V stacked materials. Int J Adv Manuf Technol 117(1):653–673

    Article  Google Scholar 

  12. Namdev S (2021) Modeling of hole geometrical features in laser drilling of AISI316L sheet. J Eng Res 1:1–15

    Google Scholar 

  13. Arrazola PJ, Garay A, Iriarte LM, Armendia M, Marya S, Le Maître F (2009) Machinability of titanium alloys (Ti6Al4V and Ti555.3). J Mater Process Technol 209(5):2223–2230

    Article  Google Scholar 

  14. Chatterjee S, Mahapatra SS, Bharadwaj V, Choubey A, Upadhyay BN, Bindra KS (2018) Quality evaluation of micro drilled hole using pulsed Nd:YAG laser: a case study on AISI 316. Lasers Manuf Mater Process 5(3):248–269

    Article  Google Scholar 

  15. Chen MF, Hsiao WT, Wang MC, Yang KY, Chen YF (2015) A theoretical analysis and experimental verification of a laser drilling process for a ceramic substrate. Int J Adv Manuf Technol 81(9–12):1723–1732

    Article  Google Scholar 

  16. Shelton JA, Shin YC (2010) Comparative evaluation of laser-assisted micro-milling for AISI 316, AISI 422, TI-6AL-4V and Inconel 718 in a side-cutting configuration. J Micromech Microeng 20(7):075012

    Article  Google Scholar 

  17. Rajesh P, Nagaraju U, Gowd GH, Vardhan TV (2017) Experimental and parametric studies of Nd:YAG laser drilling on austenitic stainless steel. Int J Adv Manuf Technol 93(1–4):65–71

    Article  Google Scholar 

  18. Muthuramalingam T, Akash R, Krishnan S, Phan NH, Pi VN, Elsheikh AH (2021) Surface quality measures analysis and optimization on machining titanium alloy using CO2 based laser beam drilling process. J Manuf Process 62:1–6

    Article  Google Scholar 

  19. Ghoreishi M, Nakhjavani OB (2008) Optimisation of effective factors in geometrical specifications of laser percussion drilled holes. J Mater Process Technol 196(1–3):303–310

    Article  Google Scholar 

  20. Moradi M, Abdollahi H (2017) Statistical modelling and optimization of the laser percussion microdrilling of thin sheet stainless steel. Laser Eng 40(4–6):375–393

    Google Scholar 

  21. Moradi M, Arabi H, Shamsborhan M (2020) Multi-objective optimization of high power diode laser surface hardening process of AISI 410 by means of RSM and desirability approach. Optik 202:163619

    Article  Google Scholar 

  22. Moradi M, Fallah MM, Jamshidi NS (2018) Experimental study of surface hardening of AISI 420 martensitic stainless steel using high power diode laser. Trans Indian Inst Met 71:2043–2050

    Article  Google Scholar 

  23. Moradi M, Moghadam MK, Shamsborhan M, Beiranvand ZM, Rasouli A, Vahdati M, Bakhtiari A, Bodaghi M (2021) Simulation, statistical modeling, and optimization of CO2 laser cutting process of polycarbonate sheets. Optik 225:164932

  24. Sahu J, Mahapatra SS, Puhan D (2013) Multi-response optimisation of electrical discharge machining process using combined approach of RSM and FIS. Int J Product Qual Manag 12(2):185–208

    Article  Google Scholar 

  25. Coelho WA, Pereira RBD, Lauro CH, Brandão LC, Davim JP (2023) Comparative study of deep drilling in the Ti-6Al-4V ELI titanium alloy using standard and high-feed rate. Int J Adv Manuf Technol 126(9):4157–4170

    Article  Google Scholar 

  26. Chatterjee S, Mahapatra SS, Bharadwaj V, Choubey A, Upadhyay BN, Bindra KS (2019) Drilling of micro-holes on titanium alloy using pulsed Nd:YAG laser: parametric appraisal and prediction of performance characteristics. Proc Inst Mech Eng Pt B: J Eng Manuf 233(8):1872–1889

    Article  Google Scholar 

  27. Padhee S, Pani S, Mahapatra SS (2011) A parametric study on laser drilling of Al/SiCp metal-matrix composite. Proc Inst Mech Eng Pt B: J Eng Manuf 226:76–91

    Article  Google Scholar 

  28. Chryssolouris G, Bredt J, Kordas S, Wilson E (1988) Theoretical aspects of a laser machine tool. J Manuf Sci Eng 110(1):65–70

    Google Scholar 

  29. Low DKY, Li L, Corfe AG (2001) Characteristics of spatter formation under the effects of different laser parameters during laser drilling. J Mater Process Technol 118(1):179–186

    Article  Google Scholar 

  30. Choubey A, Vishwakarma SC, Misra P, Jain RK, Agrawal DK, Arya R, Upadhyaya BN, Oak SM (2013) A highly efficient and compact long pulse Nd:YAG rod laser with 540 J of pulse energy for welding application. Rev Sci Instrum 84(7):073108–1–8

  31. Upadhyaya BN, Vishwakarma SC, Choubey A, Jain RK, Ali S, Agrawal DK, Nath AK (2008) A highly efficient 5kW peak power Nd:YAG laser with time-shared fiber optic beam delivery. Opt Laser Technol 40(2):337–342

    Article  Google Scholar 

  32. Kuar AS, Doloi B, Bhattacharyya B (2006) Modelling and analysis of pulsed Nd:YAG laser machining characteristics during micro-drilling of zirconia (ZrO2). Int J Mach Tools Manuf 46(12):1301–1310

  33. Biswas R, Kuar AS, Mitra S (2014) Multi-objective optimization of hole characteristics during pulsed Nd:YAG laser microdrilling of gamma-titanium aluminide alloy sheet. Opt Lasers Eng 60:1–11

    Article  Google Scholar 

  34. Wang H, Liu J, Xu Y, Wang X, Ren N, Ren X, Hu Q (2021) Experimental characterization and real-time monitoring for laser percussion drilling in titanium alloy using transverse electric field assistance and/or lateral air blowing. J Manuf Process 62:845–858

    Article  Google Scholar 

  35. Wang W, Song H, Liao K, Mei X (2021) Water-assisted femtosecond laser drilling of 4H-SiC to eliminate cracks and surface material shedding. Int J Adv Manuf Technol 112(1):553–562

    Article  Google Scholar 

  36. Lazzini G, Lutey AHA, Romoli L, Groppetti R (2022) High precision feature detection in laser texturing. Precis Eng 73:183–194

    Article  Google Scholar 

  37. Chatterjee S, Mahapatra SS, Sahu AK, Bhardwaj VK, Choubey A, Upadhyay BN, Bindra KS (2017) Experimental and parametric evaluation of quality characteristics in Nd:YAG laser micro-drilling of Ti6Al4V and AISI 316. In Gas Turbine India Conference (Vol. 58516, p. V002T10A006). American Society of Mechanical Engineers

Download references

Funding

The work is financially supported by the National Natural Science Foundation of China (Grant No. 52175425) and the Shanghai Industrial Collaborative Innovation Project (Grant No. HCXBCY-2022–040). This publication has emanated from research supported by a research grant from Science Foundation Ireland (SFI) under grant number 16/RC/3872 and is co-funded by the European Regional Development Fund and I-Form industry partners.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology, Rourkela, India

    Suman Chatterjee & Siba Sankar Mahapatra

  2. I-Form Advanced Manufacturing Centre Research and Advanced Processing Technology Research Centre, School of Mechanical and Manufacturing Engineering, Dublin City University, Glasnevin, Dublin 9, Ireland

    Suman Chatterjee & Dermot Brabazon

  3. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, People’s Republic of China

    Jinyang Xu

Authors
  1. Suman Chatterjee
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Siba Sankar Mahapatra
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jinyang Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Dermot Brabazon
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Suman Chatterjee, Siba Sankar Mahapatra, Jinyang Xu, and Dermot Brabazon contributed to the conception of the study. Suman Chatterjee performed the experiment and wrote the manuscript. Siba Sankar Mahapatra, Jinyang Xu, and Dermot Brabazon helped perform the analysis with constructive comments and reviewed the manuscript.

Corresponding author

Correspondence to Jinyang Xu.

Ethics declarations

Conflict of interest

The authors declare that there are no known competing financial interests or personal relationships with respect to the research, authorship, and publication of this article.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Chatterjee, S., Mahapatra, S.S., Xu, J. et al. Influence of parameters on performance characteristics and defects during laser microdrilling of titanium alloys using RSM. Int J Adv Manuf Technol 129, 4569–4587 (2023). https://doi.org/10.1007/s00170-023-12525-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-12525-4

Keywords

Search

Navigation