Direct 3D femtosecond laser manufacturing of SOFC

Additive manufacturing (AM), esp. laser AM, becomes a powerful tool to replace conventional methods such as thermo-mechanical processing, physical vapor deposition (PVD), Plasma spraying, etc., due to its cost effectiveness and capability of making complex structure and composition. However, direct metal melting of high temperature multi- component (hybrid) materials is still a challenging field, mainly due to limited understanding of composition control, laser melting control, and melted structure formation and phase transition. An ultra-short pulsed (USP) fiber laser AM technique will be developed to control melting temperature and feeding powders with precision. Its melting temperature can be controlled with pulse repetition rate and energy. Its feeding rate can be controlled by mixed powder assisted by fs laser ablation. An ultra-short pulsed (USP) fiber laser 3D printing technique will be developed for high temperature hybrid materials with sufficient thermal fatigue resistance and mechanical strength. It will enable a new and cost effective process for 3D printing of fuel cells. Commercial Applications and Other Benefits: In addition to the metal 3D AM applications, material processing is another major commercial application for this project. This includes (1) Photonic device fabrications, such as waveguide, coupler, WDM, modulator, and switching; (2) all types of metal processing such as welding, cutting, annealing, and drilling; (3) semiconductor and microelectronics manufacturing such as lithography, inspection, control, defect analysis and repair, and via drilling; (4) marking of all materials including plastic, metals, and silicon; (5) other materials processing such as rapid prototyping, desk top manufacturing, micromachining, photofinishing, embossed holograms, and grating manufacturing.