Gene Zak PhD, P.Eng

Associate Professor

Mechanical and Materials Engineering, Faculty
Phone: 613-533-2567
Fax: 613-533-6489
McLaughlin Hall, Room: 207

Expertise: Laser welding of plastics, Laser-based Precision Manufacturing, Additive Manufacturing
Gene Zak
Research Teaching Publications Open Positions

Areas of Research 

Laser Welding of Plastics 

Laser transmission welding is a relatively new joining process in which laser energy is used to melt polymer at the interface between laser-transparent and laser-absorbing components. Past work (2003) in collaboration with Prof. Bates (RMC) and Prof. Kontopoulou (Chemical Engineering, Queen's) examined the effect of diode laser speed, power, beam area and weld pressure on the meltdown, microstructure and weld strength of T-joints made from unreinforced nylon 6. The results showed that meltdown increases strongly with line energy and is also affected by beam area and weld pressure. For the range of parameters selected, the strength was observed to depend largely on the ability to make welds free of local stress concentrations and degraded material. 
Laser machining has been applied for many years as an alternative to conventional machining methods for hard-to-machine materials. Laser machining is a non-contact technique, with no tool wear and no cutting force applied to the machined material. For these reasons it is well suited for ceramics due to the extreme hardness and brittleness of these materials. The above characteristics make machining of ceramics using conventional techniques very difficult, expensive and often impossible. Ceramics are most commonly formed by casting the shapes directly (which is can be inaccurate due to shrinking during the firing process) and/or diamond grinding, which is slow, expensive and limited in the shapes that can be created. Laser machining allows direct shaping of the fired ceramic, bringing with it the potential of building a wide variety of shapes with high accuracy. 
Past work has been carried out in collaboration with Prof. Krstic (former director of CMACN). Laser machining parameters were studied (2004) to optimize the laser machining of pockets in aluminum nitride for high material removal rates and minimum surface roughness. The parameters were determined by machining single-layer rectangular pockets. Using a 10W Nd:YLF laser with a 3-axes motion system (part of the RLT lab facilities), a maximum material removal rate of 0.019 mm3/s and a minimum surface roughness of Ra=0.29 mm were achieved. 
A versatile Laser Ceramics Machining System was designed and built as part of the former Centre for Manufacturing of Advanced Ceramics and Nanomaterials (CMACN). Together with a 6-axis motion system and two X-Y beam scanners, the system will feature three laser sources: 
  • UV-frequency, 7-W diode-pumped solid-state laser (Coherent AVIA 355-7000) 
  • 1,064 nm wavelength, 100W solid-state Nd:YAG laser (Lee Laser LDP-100MQ) 
  • 10,600 nm wavelength, 250 W CO2 laser (Coherent K-250) 
The system has been in operation since 2004 was operational from 2004 until about 2015.
Facilities 

Past Research 

  • Robotic Interception of Moving Targets 
  • Active Vision System for Object Recognition 
  • Robot Calibration 
  • Kinematic Modeling of Modular Robots
  • MECH 455 Computer Integrated Manufacturing 
  • Blackford, G. Zak, I.Y. Kim, “The effect of scan path on thermal gradient during selective laser melting,” International Journal of Advanced Manufacturing Technology, DOI 10.1007/s00170-020-05899-2, Aug 2020.
  • Ghasemi, Y. Zhang, P. J. Bates, D. Duquesnay, G. Zak, “Effect of Processing Parameters on Meltdown in Quasi-Simultaneous Laser Transmission Welding,” Optics and Lasers Technology, Vol. 107, pp. 244-252, Nov 2018.
  • Lakemeyer, P. J. Bates, V. Schoeppner, B. Zazoum, G. Zak, D. DuQuesnay, “Matching of Laser Intensity Distribution for Laser Transmission Welding of Thermoplastics,” Welding in the World, 2017-08 (DOI 10.1007/s40194-017-0501-6).
  • X.F. Xu, A. Parkinson, P.J. Bates, G. Zak, “Effect of part thickness, glass fiber and crystallinity on light scattering during laser transmission welding of thermoplastics,” Optics and Laser Technology, Vol. 75, pp. 123-131, Dec 2015. 
  • X.F. Xu, P.J. Bates, G. Zak, “Effect of glass fiber and crystallinity on light transmission during laser transmission welding of thermoplastics,” Optics and Lasers Technology, Vol. 69, pp. 133-139, Jun 2015.
  • Chen, G. Zak, P. J. Bates, “Absorption Coefficient Measurement in Laser Transmission Welding of Thermoplastics,” International Polymer Processing, Vol. 30, No. 1, pp. 38-43, 2015.
  • Chen, G. Zak, P. Bates, “Description of transmitted energy during Laser Transmission Welding of polymers”, Welding in the World, IIW-2323-11, Vol. 57, No. 2, pp. 171-178, Jan/Feb 2013.
  • Azhikannickal, P. J. Bates, G. Zak, “Laser light transmission through thermoplastics as a function of thickness and laser incidence angle: Experimental and Modeling,” ASME Journal of Manufacturing Science and Engineering, Vol. 134, No. 6, pp. 061007-1 to 6, Dec 2012.
  • Azhikannickal, P. Bates, G. Zak, “Thermal Imaging Technique to Characterize Laser Light Reflection from Thermoplastics,” Optics and Laser Technology, Vol. 44, No. 5, pp. 1456-1462, Jul 2012.
  • Azhikannickal, P. Bates, G. Zak, “Use of Thermal Imaging to Characterize Laser Light Reflection from Thermoplastics as a Function of Thickness, Laser Incidence Angle and Surface Roughness,” Optics and Laser Technology, Vol. 44, No. 5, pp. 1491-1496, Jul 2012.
  • Chen, P. Bates, G. Zak, M. McLeod, B. Baylis, "Experimental study on gap bridging in contour Laser Transmission Welding of polycarbonate and polyamide," Polymer Engineering & Science, Vol. 51, No. 8, pp. 1626-1635, Aug 2011.
  • Chen, P. Bates, G. Zak, "Effect of carbon black on light transmission in laser welding of thermoplastics," Journal of Materials Processing Technology, Vol. 211, No. 1, pp. 43-47, Jan 2011.
  • Y. Wang, P. J. Bates, G. Zak, "Optical properties characterization of thermoplastics used in laser transmission welding: Scattering and Absorbance," Advanced Materials Research, Vols. 97-101, pp. 3836-3841, Mar 2010.
  • L.S. Mayboudi, A.M. Birk, G. Zak, P.J. Bates, "Finite volume model for laser-soot interaction for a laser transmission welding process," Journal of Laser Applications, Vol. 22, No. 1, pp. 22-28, Feb 2010.
  • Kritskiy, G. Zak, P.J. Bates, "Laser Transmission Welding of nylon tubes and plates - experimental," Journal of Manufacturing Science and Engineering, Vol. 132, pp. (051002)1-8, Oct 2010.
  • Zak, L. Mayboudi, M. Chen, P. J. Bates, M. Birk, "Weld line transverse energy density distribution measurement in Laser Transmission Welding of thermoplastics," Journal of Materials Processing Technology, Vol. 210, No. 1, pp. 24-31, Jan 2010.
  • Chen, G. Zak, P.J. Bates, "3D finite element modeling of contour laser transmission welding of polycarbonate," Welding in the World, Vol. 53, No. 7/8, Jul/Aug 2009.
  • L.S. Mayboudi, A.M. Birk, G. Zak, P.J. Bates, "A three-dimensional thermal finite element model of laser transmission welding for lap-joint," International Journal of Modelling and Simulation, Vol. 29, No. 2, pp. 149-155, 2009. 
  • L.S. Mayboudi, A.M. Birk, G. Zak, P.J. Bates, " Infrared observations and finite element modeling of a laser transmission welding process," Journal of Laser Applications, Vol. 21, No. 3, pp. 111-118, 2009.
  • J. Bates, S. Tan, G. Zak, M. McLeod, "Shear strength and meltdown behavior of reinforced polypropylene assemblies made by resistance welding," Composites Part A: Applied Science and Manufacturing (Paper No. JCOMA-07-592), Vol. 40, No. 1, pp. 28-35, Jan 2009.
  • Chen, G. Zak, P.J. Bates, "Estimating contour Laser Transmission Welding start-up conditions using a novel non-contact method," Welding in the World, IIW-1912-08, Vol. 52, No. 11/12, pp. 71-76, Nov/Dec 2008.
  • Chen, J. Jeswiet, P.J. Bates, G. Zak, "Experimental study on sheet metal bending with medium-power diode laser," Proceedings of the Institution of Mechanical Engineers, Part B, Journal of Engineering Manufacture, Vol. 222, No. 3 , pp. 381-389, Mar 2008.
  • Alami, G. Zak, "Embedded capacitive displacement sensing within laminated metal structures," to be published in AES Technical Reviews International Journal, Part B: IJAMAIM - International Journal of Advances in Mechanics and Applications of Industrial Materials, Vol. 1, No. 1, pp. 27-34, 2008.
  • L-Y Yuen, G. Zak, S. Waldman, A. Docoslis, "Morphology of fibroblasts grown on substrates formed by dielectrophoretically aligned carbon nanotubes," Cytotechnology, Vol.56, No. 1, pp. 9-17, Jan 2008.
  • L.S. Mayboudi, A.M. Birk, G. Zak, P.J. Bates, "Effect of Soot Particles on the Laser Absorption by Thermoplastics in Laser Welding," AES Technical Reviews International Journal, Part A: IJNAEM - International Journal of Nano and Advanced Engineering Materials, Vol. 1, No.1, pp. 47-55, 2008. 
  • Y.Z. Wan, G. Zak, S. Naumann, S. Redekop, I. Slywynska, Y. Jiang, "Study of 2.5-D glass-fabric-reinforced light-curable resin composites for orthotic applications," Composites Science and Technology, Vol. 67, No. 13, pp. 2739-2746, Oct 2007. 
  • L.S. Mayboudi, A.M. Birk, G. Zak, P.J. Bates, "Thermal imaging studies and 3-D thermal finite element modelling of laser transmission welding of thermoplastics for a lap-joint configuration," ASME Journal of Heat Transfer, Vol. 129, No. 9, pp. 1177-1186, Sep 2007.
  • Gilbert, V. Krstic, G. Zak, "Machining of aluminium nitride with ultra-violet and near-infrared Nd:YAG lasers," Journal of Materials Processing Technology, Vol.189, Nos. 1-3, pp.409417, Jul2007.
  • Y. Wang, P.J. Bates, M. Aghamirian, G. Zak, R. Nicholls, M. Chen, "Quantitative morphological analysis of carbon black in polymers used in laser transmission welding," Welding in the World, Vol. 51, No. 3/4, pp. 85-90, Mar/Apr 2007.
  • L.S. Mayboudi, A.M. Birk, G. Zak, P.J. Bates, "A 3-D thermal model for spot laser transmission welding of thermoplastics," Welding in the World, Vol. 51, Nos. 1/2, pp.74-78, 2007 (IIW-1774-06). 
  • C.A. Bellemare-Davis, K. Karan, J.G. Pharoah, G. Zak, "The analysis and design of microchannel reactors," Advanced Materials Research, Vols. 15-17, pp. 321-326, 2007. 
  • L.S. Mayboudi, A.M. Birk, G. Zak, P.J. Bates, "A 2-D thermal model for Laser Transmission Welding of thermoplastics," Journal of Laser Applications, Vol. 18, No. 3, pp. 192-198, Aug.2006.
  • Prabhakaran, M. Kontopoulou, G. Zak, P. Bates, B. Baylis, "Contour laser-transmission welding of glass reinforced nylon 6," Journal of Thermoplastic Composite Materials, Vol. 19, No. 4, pp.427-439, Jul 2006.
  • Prabhakaran, M. Kontopoulou, P. Bates, G. Zak, V. Sidiropoulous, "Simulation of heat transfer in laser transmission welding," International Polymer Processing, Vol. 20, No. 4, pp. 410-416, 2005.

 

  • Conference Publications 
  • P.J. Bates, G. Zak, A. Parkinson, “Modelling laser light transmission in thermoplastic composites using Monte-Carlo simulation,” ANTEC 2019, March 18-21, Detroit, MI, Society of Plastics Engineers, 2019.
  • Ghasemi, Y. Zhang, P. J. Bates, D. Duquesnay, G. Zak, "Experimental methods to detect degradation at the weld caused by laser transmission welding," ANTEC 2016, Indianapolis, Indiana, Society of Plastics Engineers, 2016.
  • P.J. Bates, G. Zak,  M. Chen, “In contour Laser Transmission Welding – How fast is fast enough,” ANTEC 2013, April 22-25, Cincinnati, OH, Society of Plastics Engineers, 2013.
  • Azhikannickal, P. Bates, G. Zak, "Laser light transmission through thermoplastics as a function of thickness and laser incidence angle: Experimental," ANTEC 2011, May 1-5, Boston, MA, Society of Plastics Engineers, Paper PENG-01-2011-0638, 2011.
  • Bates, S. Khosravi, G. Zak, "Polymer degradation during contour Laser Transmission Welding," ANTEC 2011, May 1-5, Boston, MA, Society of Plastics Engineers, Paper PENG-11-2010-0168, 2011.
  • Cao, P. Bates, G. Zak, "Weld Read-Through Defects in Laser Transmission Welding," SAE 2011 Congress, Apr 12-14, Detroit, MI, Paper 11M-0373 (2011-01-0476), 2011.
  • Furlan, G. Zak, "Effect of grain size on the laser machinability of alumina," ICALEO 2009, Nov 2-5, Orlando, FL, pp. 1086-1091.
  • Y. Wang, P. J. Bates, G. Zak, "Optical properties characterization of thermoplastics used in laser transmission welding: transmittance and reflectance," ANTEC 2009, Jun 22-24, Chicago, IL, Society of Plastics Engineers, 2009.
  • Chen, G. Zak, P.J. Bates, M.R. Kamal, M. Al-Wohoush, "Finite element modeling and microstructure analysis for contour laser transmission welding of glass fibre reinforced nylon 6," ANTEC 2009, Jun 22-24, Chicago, IL, Society of Plastics Engineers, Paper ANTEC- 0430-2009.
  • Kritskiy, G. Zak, P.J. Bates, "Laser welding of nylon tubes to plates using conical mirrors," ANTEC 2009, Jun 22-24, Chicago, IL, Society of Plastics Engineers, Paper ANTEC- 0434 -2009.
  • L.S. Mayboudi, A.M. Birk, G. Zak, P.J. Bates, " Infrared observations of a laser transmission welding process and finite element modeling," Paper #605, ICALEO 2008, Oct 20-23, Temecula, CA, pp. 303-310. 
  • L.S. Mayboudi, A.M. Birk, G. Zak, P.J. Bates, " A finite volume model for laser-soot interaction for a laser transmission welding process," Paper #604, ICALEO 2008, Oct 20-23, Temecula, CA, pp. 294-302.
  • Chen, G. Zak, P.J. Bates, "3D finite element modeling of contour laser transmission welding of polycarbonate," International Institute of Welding Annual Assembly (IIW 2008), Jul 6-11, Graz, Austria.
  • Chen, G. Zak, P.J. Bates, "Prediction of gap bridging in laser transmission welding of amorphous polymers," ANTEC 2008, May 4-8, Milwaukee, Wisconsin, Society of Plastics Engineers, Paper ANTEC-0266-2008.
  • Alami, G. Zak, "Embedded capacitive displacement sensing within laminated metal structures," AES-ATEMA 2007 conference, Montreal, Canada, Aug 6-10, 2007.
  • L.S. Mayboudi, A.M. Birk, G. Zak, P.J. Bates, "Effect of Soot Particles on the Laser Absorption by Thermoplastics in Laser Welding," AES-ATEMA 2007 conference, Montreal, Canada, Aug 6-10, 2007.
  • Chen, G. Zak, P.J. Bates, M. McLeod, D. Rouison, "Surface damage threshold in laser transmission welding of polycarbonate," ANTEC2007, May 6-11, Cincinnati, OH, Society of Plastics Engineers, pp. 2798-2802.
  • Chen, G. Zak, P.J. Bates, B. Baylis, "Gap bridging in laser transmission welding of PA6," ANTEC2007, May 6-11, Cincinnati, OH, Society of Plastics Engineers, pp. 2788-2792.
  • L.S. Mayboudi, A.M. Birk, G. Zak, P.J. Bates, "A 3-D thermal model of laser transmission contour welding for a lap joint," ANTEC 2007, May 6-11, Cincinnati, OH, Society of Plastics Engineers, pp. 2813-2817.
  • Chen, G. Zak, P.J. Bates, B. Baylis, M. McLeod, "Method of evaluating shear strengths in contour laser transmission welding," 2007 SAE World Congress, Paper # 2007-01-0571.
  • L.S. Mayboudi, A.M. Birk, G. Zak, P.J. Bates, "Thermal imaging studies and 3-D finite element modeling for laser transmission welding of thermoplastics in a lap-joint," ASME International Mechanical Engineering Congress and Exposition, Chicago, IL, Nov 5-10, 2006, Paper # IMECE2006-13780. 
  • L.S. Mayboudi, A.M. Birk, G. Zak, P.J. Bates, "A three-dimensional finite element thermal model for laser transmission welding of thermoplastics," The 15th IASTED International Conference on Applied Simulation and Modelling, June 26-28, 2006, Rhodes, Greece, pp.531-536. 
  • C.A. Bellemare-Davis, K. Karan, J.G. Pharoah, G. Zak, "The analysis and design of microchannel reactors," submitted to THERMEC' 2006, Vancouver, BC, Feb 2006.
  • Tan, G. Zak, P. Bates, J. Mah, "Resistance welding of glass-fiber-reinforced PP: modeling and experiments," Proceedings of ANTEC 2006, May 7-11, Charlotte, NC, Society of Plastics Engineers, pp. 2236-2240.
  • L.S. Mayboudi, M. Chen, G. Zak, A.M. Birk, P.J. Bates, "Characterization of beam profile for high-power diode lasers with application to laser welding of polymers," Proceedings of ANTEC 2006, May 7-11, Charlotte, NC, Society of Plastics Engineers, pp. 2274-2278.
  • Chen, G. Zak, P.J. Bates, "Laser absorption coefficient measurement of amorphous polymers for Laser Transmission Welding," Proceedings of ANTEC 2006, May 7-11, Charlotte, NC, Society of Plastics Engineers, pp. 2291-2295.
  • Tan, G. Zak, P. Bates, J. Mah, "Resistive Implant Welding of Glass Fiber Reinforced Polypropylene Compounds," Paper # 06M-217, 2006 SAE World Congress, April 3-6, Cobo Center, Detroit, Michigan.
  • L.S. Mayboudi, A.M. Birk, G. Zak, P.J. Bates, "A 2-D thermal model for Laser Transmission Welding of thermoplastics," Paper #805, ICALEO 2005, Oct 29- Nov 4, Miami, Florida, pp. 402-409.
  • Al-Alami, G. Zak, "Finite Element Model of the Laminated Metal Tooling injection mould insert," Proceedings of 14th International Conference on Flexible Automation & Intelligent Manufacturing - FAIM2004, Ryerson University, Toronto, Ontario, Jul 12-14, 2004, Vol. 2, pp. 1025-1032.
  • Gilbert, V. Krstic, G. Zak, "Laser machining of single-layer pockets in Aluminum Nitride plates," Symposium on Materials in Mechanical Engineering - CSME Forum 2004, London, Ontario, Jun2004.

 

There are no openings at this time. 



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