Extremely High Speed Laser Application(EHLA) for Titanium Cylinder Bores using Mirror Assisted Fiber Optic Relay (MAFOR) System

This project aims to develop an Extremely High-Speed Laser Application (EHLA) Internal Diameter (ID) coating system utilizing Mirror Assisted Fiber Optic Relay (MAFOR) system for the efficient coating of hydraulic cylinder internal bores. Conventional coating methods generate excessive Heat-Affected Zones (HAZ), leading to delamination and reduced fatigue life. The EHLA process minimizes heat input by pre-melting powder prior to deposition, resulting in defect-free, metallurgically bonded coatings. Phase I Base focuses on (1) designing and validating MAFOR optics for uniform beam delivery in confined geometries, (2) evaluating and down-selecting coating materials, (3) developing an argon shielding system to prevent oxidation, and (4) establishing benchmark surface texture requirements and assessing post-clad machining/grinding for optimal lubricity. Coatings will be deposited using EHLA OD systems as a proxy for ID trials. Phase I Option involves the fabrication and validation of a prototype EHLA ID tool. Deposition trials using down-selected coatings will refine process parameters, followed by microstructural and mechanical evaluations to ensure adhesion, wear resistance, and minimal HAZ.This technology aims to extend the service life of hydraulic components and lay the foundation for Phase II, where the system will be optimized for Navy applications and broader commercial adoption in aerospace, automotive, and industrial sectors.