Research Equipment (REG): A High Power Laser and Microscopic Image Analysis System

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A high power laser and microscopic image analysis system will be used to perform controlled experiments on multilayered ceramic thermal barrier coatings. These coatings are developed for high- temperature applications such as diesel engines, jet engines and gas turbines used in land and aerospace vehicles. Current research performed by subjecting coated specimens to low heat fluxes has resulted in identifying some of the failure modes. It is now necessary to subject similar specimens, as well as specimen with thin multi-layer coatings to large heat fluxes in order to obtain larger temperatures and temperature gradients. The cracking process occurring during the application of the high heat flux will be quantified interactively using the microscopic image analysis system. The fundamental understanding that this research will provide will be used to develop and design multilayer coatings with a significantly longer life under high temperature. The second program is a multidisciplinary investigation to develop a thermally enhanced processing technique in order to improve the productivity and surface quality in the machining of ceramics. The approach is to locally heat the surface of the workpiece by using a high power laser beam in front of the cutting tool edge so as to soften the material and increase the ductility. It is anticipated that this hybrid technique can allow for machining of the difficult-to-cut materials. Thereby reducing the cost to fabricate ceramic parts and improving dimensional and surface quality. The research seeks to perform experimental investigation by constructing a testbed, to develop models for heat transfer and surface deformation along with crack propagation, and to implement a control scheme based on the process models. In- process sensing techniques pertinent to process control will be developed as well.