Micromachining of a thin film by laser ablation using femtosecond laser with masks

A gold thin film was machined by laser ablation using a femtosecond laser with mask patterns in the shape of lines and numbers. The patterns were successfully transferred with proper focusing and laser fluence. The optimal femtosecond laser fluence to keep the line width was about 5.2 mJ/cm² on the mask, and 99 mJ/cm² on the film. The processing resolution was 13 μm, and the narrowest line width was about 4 μm.     

Thermal characteristics of double-layer thin film target ablated by femtosecond laser pulses

Thermal characteristics of tightly-contacted copper--gold double-layer thin film target under ablation of femtosecond laser pulses are investigated by using a two-temperature theoretical model. Numerical simulation shows that electron heat flux varies significantly on the boundary of copper--gold film with different maximal electron temperature of 1.15×10³ K at 5 ps after ablating laser pulse in gold and copper films, which can reach a balance around 12.6 ps and 8.2 ps for a single and double pulse ablation, respectively, and in the meantime, the lattice temperature difference crossing the gold--copper interface is only about 0.04×10³ K at the same time scale. It is also found that electron--lattice heat relaxation time increases linearly with laser fluence in both single and double pulse ablation, and a sudden change of the relaxation time appears after the laser energy density exceeds the ablation threshold.     

Sub-micron ablation of metallic thin film by femtosecond pulse laser

The ability to machine very small features in a material has a wide range of applications in industry. We ablated holes into thin film of 100 nm thickness made from various metals by femtosecond pulsed laser ablation. Using a Ti:Sapphire laser which supplies a laser pulse of 150 fs duration at central spectrum wavelength of 400 nm, we have produced a series sub-micron holes, whose diameters are less than 200 nm with a focused laser spot of 1.7 μm. We found that the material damage threshold has a great influence on the quality of the produced features. Experimental results shows that the heat-affected zone and the degree of being affected reduce with the increase of threshold value.     

Single-shot ablation threshold of chromium using UV femtosecond laser pulses

Single-shot ablation threshold for thin chromium film was studied using 266 nm, femtosecond laser pulses. Chromium is a useful material in the nanotechnology industry and information on ablation threshold using UV femtosecond pulses would help in precise micromachining of the material. The ablation threshold was determined by measuring the ablation crater diameters as a function of incident laser pulse energy. Absorption of 266 nm light on the chromium film was also measured under our experimental conditions, and the absorbed energy single-shot ablation threshold fluence was \(46 \pm 5\)  mJ/cm². The experimental ablation threshold fluence value was compared to time-dependent heat flow calculations based on the two temperature model for ultrafast laser pulses. The model predicts a value of 31.6 mJ/cm² which is qualitatively consistent with the experimentally obtained value, given the simplicity of the model.     

THz generation via optical rectification with ultrashort laser pulse focused to a line

We report on efficient THz pulse generation via optical rectification with femtosecond laser pulses focused to a line by a cylindrical lens. This configuration provides phase-matched conditions in the superluminal regime. 35 pJ THz pulses have been generated with this technique in a stoichiometric LiNbO₃ crystal pumped by 2 μJ femtosecond laser pulses at room temperature. An unusual superquadratic rise of the THz pulse energy with the laser pulse energy has been observed at high laser energies. This extraordinary energy dependence of the THz generation efficiency is explained by self-focusing of the laser beam in the crystal. Z-scan measurements and comparison of the THz pulse spectra created with laser pulses having different energies confirm this interpretation.     

New ablation experiment aimed at metal expulsion at the hydrodynamic regime

The effects of nanosecond visible laser on metallic materials have been studied experimentally. High laser energies (>10¹³ W/cm²) created a hydrodynamic regime, where the ablation pressure and the ensuing shock wave are the main mechanisms for material expulsion. Plasma shielding caused a constant material removal despite the increase of energy, while the increase of number of pulses resulted in an almost linear increase of the crater volume, despite the lower depths reached with every subsequent pulse. Our results show that there is a correlation between ablation efficiency and material properties, namely ablation efficiency decreases with melting temperature and bulk modulus.     

Elimination of cracking during UV laser ablation of SrTiO3 single crystals by employing a femtosecond laser

We have performed a comparative study of UV laser ablation of SrTiO₃ with nanosecond- and sub-picosecond sources, respectively. The experiments were performed with lasers at a wavelength of 248 nm and pulse durations of 34 ns and 500 fs. Femtosecond ablation turns out to be more efficient by one order of magnitude and eliminated the known problem of cracking of SrTiO₃ during laser machining with longer pulses. In addition, the cavities ablated with femtosecond pulses display a smoother surface with no indication of melting and well-defined, sharp edges. These effects can be explained by the reduced thermal shock effect on the material by using ultrashort pulses.     

飞秒激光烧蚀LiNbO3晶体的形貌特征与机理研究

采用了不同能量的单脉冲和多脉冲飞秒激光对LiNbO₃晶体进行烧蚀，并刻蚀了表面衍射型光栅.通过扫描电镜和原子力显微镜观察了烧蚀点的形貌特征，首次发现利用单束飞秒激光脉冲对LiNbO₃晶体烧蚀，可以得到超衍射极限的烧蚀点，当聚焦光斑直径约为2μm、能量为170nJ的单脉冲飞秒激光作用时，烧蚀点的直径约为400nm，100nJ，17个脉冲作用时烧蚀点的直径约为800nm.同时可以观察到在能量较低的多脉冲飞秒激光作用下， LiNbO₃晶体呈现出大约200nm周期性分布的波纹状结构.实验结果表明，选择合适参数的飞秒激光脉冲可以对LiNbO₃晶体进行超衍射极限加工，这对于利用飞秒激光制作LiNbO₃基质的微纳光电子器件有十分重要的意义.     

Formation of nanostructures by an intense femtosecond pulse laser irradiating Au film on sapphire substrate

We investigate the morphology change of Au film on sapphire substrate by irradiating with a 1 kHz femtosecond pulse laser. Under observation of a scanning electron microscope, a textured nanostructure was formed in the exposed area on Au film due to laser ablation and subsequent stress relaxation. This process was strongly determined by the laser intensity profile and the dynamics of molten liquid. With the increasing of laser pulses number, the Au film was broken down and then a few polarization-dependent nanoripples arranged in the same direction appeared on the sapphire surface, which may result from a spatial modulation of energy due to the interference between the incident light and the excited surface plasmon polaritons. In addition, we used an energy dispersive spectrometer to analyze the chemical composition of nanoripples on the surface and in the ablated crater, respectively. The changes of O and Al elements implied that a complicated chemical transformation participated in the nanoripples formation process. We believe that present results are very useful for the analysis of the interaction between femtosecond laser and solids, especially the film material.     

Femtosecond-pulse laser ablation of human corneas

A femtosecond pulse laser in the visible spectral region shows promise as a potentially new powerful corneal sculpting tool. It combines the clinical and technical advantages of visible wavelengths with the high ablation quality observed with nanosecond-pulse excimer lasers at 193 nm. A femtosecond and a nanosecond dye laser with pulse durations of 300 fs and 7 ns, and centre wavelengths at 615 nm and 600 nm, respectively, both focused to an area of the order of 10^–5 cm², have been applied to human corneal ablation. Nanosecond laser pulses caused substantial tissue disruption within a 30–100 m range from the excision edge at all fluences above the ablation threshold of F _th60 J cm^–2 (I _th9 GW cm^–2). Completely different excisions are produced by the femtosecond-pulse laser: high quality ablations of the Bowman membrane and the stroma tissue characterised by damage zones of less than 0.5 m were observed at all fluences above ablation threshold of F _th1 J cm^–2 or I _th3 TW cm^–2 (3×10¹² W cm^–2). The transparent cornea material can be forced to absorb ultrashort pulses of extremely high intensity. The fs laser generates its own absorption by a multiphoton absorption process.     

Nanosecond and femtosecond ablation of La0.6Ca0.4CoO3: a comparison between plume dynamics and composition of the films

Thin films of La_0.6Ca_0.4CoO₃ were grown by pulsed laser ablation with nanosecond and femtosecond pulses. The films deposited with femtosecond pulses (248 nm, 500 fs pulse duration) exhibit a higher surface roughness and deficiency in the cobalt content compared to the films deposited with nanosecond pulses (248 nm, 20 ns pulse duration). The origin of these pronounced differences between the films grown by ns and fs ablation has been studied in detail by time-resolved optical emission spectroscopy and imaging. The plumes generated by nanosecond and femtosecond ablation were analyzed in vacuum and in a background pressure of 60 Pa of oxygen. The ns-induced plume in vacuum exhibits a spherical shape, while for femtosecond ablation the plume is more elongated along the expansion direction, but with similar velocities for ns and fs laser ablation. In the case of ablation in the background gas similar velocities of the plume species are observed for fs and ns laser ablation. The different film compositions are therefore not related to different kinetic energies and different distributions of various species in the plasma plume which has been identified as the origin of the deficiency of species for other materials.     

Surface foaming of collagen, chitosan and other biopolymer films by KrF excimer laser ablation in the photomechanical regime

Collagen, an important material made of a protein of the extracellular matrix, was extracted from rat tail tendons by acetic acid dissolution, and dry glassy films (15% water content) with smooth surfaces were casted from the solution with a thickness of ∼25 μm. Collagen and similar biopolymer films surface were exposed to single pulses of radiation of the KrF laser with increasing fluence. A white damaged area appears on the treated surface at a threshold of 0.5 J/cm² with a single pulse and becomes more visible for higher fluence. SEM and profilometry of the ablated surface displays an important swelling (∼5–7 μm) and a microscopic foam structure indicative of the laser induced expansion of the excited material. This process is due to the explosive ablation (a critical phenomenon also called explosive boiling or phase explosion) of the irradiated material and produces upon laser heating a high concentration of bubbles within the polymer because of the relatively large absorption depth (20 μm) and the presence of a large amount of water in the material. Further bubble colliding and bursting produces a three-dimensional polymer micro-foam with interconnected pores. This is the first this result has been reported. The laser induced micro-foam may display some interesting properties for new applications. PACS 42.62; 61.82; 42.70-aThis revised version was published online in June 2005 with corrections to equations 7, 9 and 10.     

PMP泡沫的飞秒激光烧蚀及切割方法

对密度为90 mg/cm3的PMP泡沫材料的飞秒激光烧蚀结果进行了分析,推导出该材料在脉宽50 fs、波长800 nm、重复频率为1000 Hz的飞秒激光作用下的蚀除阈值为0.91 J/cm2（100个激光脉冲）,获得了烧蚀直径分别随激光功率、脉冲数及聚焦物镜数值孔径的变化规律。相同飞秒激光加工系统下,对比了铜箔上获得的烧蚀形状,确定了PMP泡沫材料本身的多孔洞及其分布不均匀是造成烧蚀区域的形状不规则的重要因素。PMP泡沫在较高能量或是较长时间的飞秒激光作用下,烧蚀区域发生碳化的原因是由热作用引发的。提出了一种基于激光束耦合的飞秒激光切割厚度大于1 mm的薄膜-泡沫材料的方法,并获得了切割厚度大于1.5 mm、切割侧壁与光束光轴夹角小于5、切割面整洁的薄片。     

Thermodynamic evolution of materials during laser ablation under pico and femtosecond pulses

Using molecular-dynamics, we study the thermodynamic evolution of a simple two-dimensional Lennard–Jones system during laser ablation for pulse durations ranging from 200 fs to 400 ps. We briefly review results previously obtained for fs pulses where the evolution of the material was shown to be solely a function of the locally absorbed energy (provided that only thermal effects are important), i.e., is adiabatic. For longer pulses (100 and 400 ps) the situation becomes more complex, as the relaxation path also depends on the position in the target and on the timescale on which expansion occurs. We show that, in contrast to fs pulses, the material ejected following ps laser irradiation does not enter the liquid–vapor metastable region before ablation occurs, hence showing that phase explosion is not the dominant mechanism in this regime. Following on from previous work, we propose that trivial fragmentation is the main ablation mechanism. PACS 79.20.Ds; 79.20.Ap; 61.80.Az     

Nanospallation induced by an ultrashort laser pulse

A femtosecond laser pulse with power density of 10¹³ to 10¹⁴ W/cm² incident on a metal target causes ablation and ejection of the surface layer. The ejected laser plume has a complicated structure. At the leading front of the plume, there is a spall layer where the material is in a molten state. The spall layer is a remarkable part of the plume in that the liquid-phase density does not decrease with time elapsed. This paper reports theoretical and experimental studies of the formation, structure, and ejection of the laser plume. The results of molecular dynamics simulations and a theoretical survey of plume structure based on these results are presented. It is shown that the plume has no spall layer when the pulse fluence exceeds an evaporation threshold F _ev. As the fluence increases from the ablation threshold F _a to F _ev, the spall-layer thickness for gold decreases from 100 nm to a few lattice constants. Experimental results support theoretical calculations. Microinterferometry combined with a pump-probe technique is used to obtain new quantitative data on spallation dynamics for gold. The ablation threshold is evaluated, the characteristic crater shape and depth are determined, and the evaporation threshold is estimated.     

Micromachining of copper using Nd:YAG laser radiation at 1064, 532, and 355 nm wavelengths

The interaction phenomena of nanosecond time period Q-switched diode-pumped Nd:YAG laser pulses using 1064, 532 and 355 nm with 0.25 mm thick pure-copper foil was investigated at an incident laser intensity range of 0.5–57.9 GW/cm². For each sample, etch rate and surface structure were determined. Analysis of the results of the tests included scanning electron microscopy (SEM). A maximum etch rate of 13.3 μm per pulse was obtained for the etch rate tests carried out at 532 nm. The maximum etch rate obtainable for 1064 nm was 2.21 μm per pulse, and for 355 nm, 6.68 μm per pulse. The dramatic decrease in etch rate observed when processing at 1064 nm is thought to occur due the highly reflective nature of copper as the interaction wavelength is increased, plus the nature of the plasma formed above the material during the high-intensity laser–material interaction. This plasma then imparts energy to the surface of the processed area leading to surface melting of the area surrounding the hole as can be seen by the SEM photographs.     

Single and multiple shot near-infrared femtosecond laser pulse ablation thresholds of copper

The single-shot ablation threshold and incubation coefficient of copper were investigated using an amplified near-infrared, femtosecond Ti:sapphire laser. To date, the near-infrared femtosecond ablation threshold of copper has been reported in the range of several hundred millijoules per cm² based primarily on multiple shot ablation studies. A careful study of the single shot ablation threshold for copper was carried out yielding an incident single-shot ablation threshold of (1.06±0.12) J/cm² for a clean copper foil surface. This was determined by measuring the diameters of the ablation spots as a function of the laser pulse energy using scanning electron microscopy for spatially Gaussian laser spots. When multiple shots were taken on the same spot, a reduction in ablation threshold was observed, consistent with a multiple shot incubation coefficient of 0.76±0.02. Similar experiments on 250 nm and 500 nm copper thin films sputtered on a silicon substrate demonstrated that scaling the threshold values with the absorbance of energy at the surface yields a consistent absorbed fluence threshold for copper of (59±10) mJ/cm². This absorbed threshold value is consistent with the expected value from a two-temperature model for the heating of copper with an electron-lattice coupling constant of g=10¹⁷ Wm^-3 K^-1. Single-shot rippling of the surface in the threshold ablation intensity regime was also observed for the foil target but not for the smooth thin film target. PACS 61.80.Ba; 61.82.Bg     

Fast femtosecond laser ablation for efficient cutting of sintered alumina substrates

Fast, accurate cutting of technical ceramics is a significant technological challenge because of these materials' typical high mechanical strength and thermal resistance. Femtosecond pulsed lasers offer significant promise for meeting this challenge. Femtosecond pulses can machine nearly any material with small kerf and little to no collateral damage to the surrounding material. The main drawback to femtosecond laser machining of ceramics is slow processing speed. In this work we report on the improvement of femtosecond laser cutting of sintered alumina substrates through optimisation of laser processing parameters. The femtosecond laser ablation thresholds for sintered alumina were measured using the diagonal scan method. Incubation effects were found to fit a defect accumulation model, with F_th,1=6.0 J/cm² (±0.3) and F_th,∞=2.5 J/cm² (±0.2). The focal length and depth, laser power, number of passes, and material translation speed were optimised for ablation speed and high quality. Optimal conditions of 500 mW power, 100 mm focal length, 2000 µm/s material translation speed, with 14 passes, produced complete cutting of the alumina substrate at an overall processing speed of 143 µm/s – more than 4 times faster than the maximum reported overall processing speed previously achieved by Wang et al. [1]. This process significantly increases processing speeds of alumina substrates, thereby reducing costs, making femtosecond laser machining a more viable option for industrial users.     

Laser-induced damage studies in GaAs

Laser-induced damage studies have been carried out on monocrystal GaAs at 1.06 μm wavelength as a function of pulse repetition rate in the nanosecond regime. The single shot observed laser damage threshold is 0.9 J/cm². It has been found that the damage threshold decreases when the sample is irradiated with large number of pulses. However, the above effect is observed only when the repetition rate is higher than 1 Hz. Various laser damage mechanism theories have been discussed to explain the results.     

Femtosecond laser ablation characteristics of nickel-based superalloy C263

Femtosecond laser (180 fs, 775 nm, 1 kHz) ablation characteristics of the nickel-based superalloy C263 are investigated. The single pulse ablation threshold is measured to be 0.26±0.03 J/cm² and the incubation parameter ξ=0.72±0.03 by also measuring the dependence of ablation threshold on the number of laser pulses. The ablation rate exhibits two logarithmic dependencies on fluence corresponding to ablation determined by the optical penetration depth at fluences below ∼5 J/cm² (for single pulse) and by the electron thermal diffusion length above that fluence. The central surface morphology of ablated craters (dimples) with laser fluence and number of laser pulses shows the development of several kinds of periodic structures (ripples) with different periodicities as well as the formation of resolidified material and holes at the centre of the ablated crater at high fluences. The debris produced during ablation consists of crystalline C263 oxidized nanoparticles with diameters of ∼2–20 nm (for F=9.6 J/cm²). The mechanisms involved in femtosecond laser microprocessing of the superalloy C263 as well as in the synthesis of C263 nanoparticles are elucidated and discussed in terms of the properties of the material.