A simple dye-sensitized solar cell sealing technique using a CO2 laser beam excited by 60 Hz AC discharges

Dye-sensitized solar cells (DSSCs) use two glass substrates (photo electrode and counter electrode) coated with fluorine-doped tin oxide (FTO) to harvest light into the cell and to collect electrons. The space between the photo electrode and the counter electrode are filled with a liquid type electrolyte for electron transfer into the cell. Therefore, an appropriate sealing method is required to prevent the liquid electrolyte leaking out. In this paper, a simple CO₂ laser beam with TEM₀₀ mode excited by a 60 Hz AC discharge was used to seal two glass substrates coated with FTO for the fabrication of DSSCs. The sealing technique improved the durability and stability of the DSSCs. The optimal conditions for the sealing of the DSSCs are related to the pin-hole diameter, the discharge current and the moving velocity of the target. Especially, the CO₂ laser beam is used as a heat source that is precisely controlled by the pin-hole, which plays an important role in adjusting its spot size. From these results, the maximum laser power was found to be 40 W at 18 Torr and 35 mA. In order to achieve the best sealing quality, the following parameters are required: a pin-hole diameter of 4 mm, input voltage of 10.73 kV, discharge current of 9.31 mA, moving velocity of 1 mm/s and distance from the target surface of 26.5 cm. Scanning electron microscope images show that the sealing quality obtained using the CO₂ laser beam is superior to that obtained using a hot press or soldering iron.     

Miniature high-repetition-rate TEA CO2 laser with surface-wire-corona preionization

In this article, an experimental study of a miniature, sealed-off, high-repetition-rate transversely excited atmospheric-pressure (TEA) CO₂ laser with a kind of surface-wire-corona preionization (SWCP) is described. We have utilized an SWCP consisting of SiO₂ dielectric tube and a fine wire strained and attached to the dielectric surface. A BN ceramic material, which has an extremely low coefficient of thermal expansion of about 5 × 10⁻⁷/°C was employed as a supporter of the resonator. A measurement on emission spectra of SWCP has been reported. By applying SWCP to the TEA CO₂ laser, efficient laser operation at an overall efficiency of 9.8% with an output energy of 150 mJ has been achieved from a small discharge volume of 25 cm³ with an active length of 230 mm. At the pulse repetition frequency of 60 Hz, the TEM₀₀ mode of laser beam with pulse width of 60 ns was obtained.     

A high polarization microchip green laser with dual Nd:YVO4 crystal

A high polarization Nd:YVO₄/KTP laser with dual crossed gain crystal is reported. Using two optical axis orthogonal Nd:YVO₄ crystal as gain medium, eliminating the depolarization effect of single Nd:YVO₄ crystal, the high polarization green laser is obtained. With 1.8 W diode laser pump power the output power of TEM₀₀ green laser is 366 mW, the light–light conversion efficiency is up to 20.3%, and the polarization ratio is 110:1. This laser has the advantages of being simple and easily attainable at a low cost, and it is suitable for batch production.     

Ablation depth control with 40 nm resolution on ITO thin films using a square,flat top beam shaped femtosecond NIR laser

We reported on the ablation depth control with a resolution of 40 nm on indium tin oxide (ITO) thin film using a square beam shaped femtosecond (190 fs) laser (λ_p=1030 nm). A slit is used to make the square, flat top beam shaped from the Gaussian spatial profile of the femtosecond laser. An ablation depth of 40 nm was obtained using the single pulse irradiation at a peak intensity of 2.8 TW/cm². The morphologies of the ablated area were characterized using an optical microscope, atomic force microscope (AFM), and energy dispersive X-ray spectroscopy (EDS). Ablations with square and rectangular types with various sizes were demonstrated on ITO thin film using slits with varying x–y axes. The stereo structure of the ablation with the depth resolution of approximately 40 nm was also fabricated successfully using the irradiation of single pulses with different shaped sizes of femtosecond laser.     

Damage/ablation morphology of laser conditioned sapphire under 1064 nm laser irradiation

The damage/ablation morphologies and laser induced damage threshold (LIDT) of three different sapphire samples: original, 1064 nm laser conditioned and 10.6 μm CO₂ laser polished substrates are investigated with ns pulses laser irradiation. The results indicate that the damage resistance capability cannot be enhanced by 1064 nm laser conditioning or CO₂ laser polishing. The damage/ablation morphology of 1064 nm-laser conditioned samples is same as that of the original sapphire. But it is different from the damage/ablation morphology of the CO₂ laser polished sapphire. The “gentle and strong” ablation phases are observed in this work and several phenomena are observed in the two ablation phases. Ripple is observed in the “gentle” ablation processes, while convex spots and raised rims are observed in the “strong” ablation processes. Meanwhile, stripe damage and pin-points are observed in the CO₂ laser conditioned sapphire after ns laser irradiation. The formation mechanisms of the phenomena are also discussed for the explanation of related damage/ablation morphology. The results may be helpful for the damage/ablation investigation of sapphire in high power laser systems.     

Diode-pumped monolithic Er3+:Yb3+:YAl3(BO3)4 micro-laser at 1.6 μm

Efficient eye-safe 1.6 μm monolithic laser was realized in a c-cut, 0.7-mm-thick Er³⁺:Yb³⁺:YAl₃(BO₃)₄ microchip end-pumped by a quasi-continuous-wave 970 nm diode laser. At incident pump peak power of 20.4 W, a maximum output peak power of 2.6 W with a slope efficiency of 19% was obtained when the waist radius of pump laser beam was 220 μm. The spectra and profiles of output beam of the Er³⁺:Yb³⁺:YAl₃(BO₃)₄ monolithic laser were measured. The influences of the waist radius of pump laser beam on the slope efficiency and threshold of the monolithic laser were also investigated.     

Pump tuned wide tunable noncritically phase-matched ZnGeP2 narrow line width optical parametric oscillator

A line tunable singly resonant noncritically phase matched narrow band width ZnGeP₂ (ZGP) optical parametric oscillator pumped by the output idler radiation from a KTA OPO based on a 20 mm long KTA crystal pumped from a Q-switched Gaussian shaped Nd:YAG laser beam with a grating having grooves density 85 lines/mm has been demonstrated in the spectral ranges of 3–7 μm. The measured threshold of oscillation energy was 10 μJ. The conversion efficiency was 20.5% and slope efficiency of the ZGP OPO was 20% using a 23 mm long ZGP crystal at 26 mm cavity length. Line width of the generated infrared radiation from ZGP OPO was 37–60 nm.     

Synthesis of Ag-deionized water nanofluids using multi-beam laser ablation in liquids

Multi-pulse laser ablation of silver in deionized water was studied. The laser beams were arranged in a cross-beam configuration. In our experiments, two single-mode, Q-switched Nd-Yag lasers operating at 1064 nm, pulse duration of 5.5 ns and 10 Hz rep rate were used. The laser fluence of the second beam was 0.265 J/cm² for all tests. Two levels of the laser fluences were used for the ablating beam: 0.09 and 0.265 J/cm² (11,014 and 33,042 J/cm² at the focal point, respectively). The silver target was at 50 mm from the cell window and 10 mm deep. The second beam was aligned parallelly with the silver target and focused at 2 mm in front of the focal point of the ablating beam. For all cases, the delay time between the ablating beam and the cross-beam was 40 μs. In general, the ablated particles were almost all spherical. For fluence of 0.09 J/cm ² and single-beam approach, the mean particle size was about 29 nm. The majority of the particles, however, were in 19–35 nm range and there were some big ones as large as 50–60 nm in size. For double-beam approach, the particles were smaller with the average size of about 18 nm and the majority of the particles were in 9–21 nm range with few big one as large as 40 nm. For the beam fluence of 0.265 J/cm² and single-beam configuration, the particle sizes were smaller, the mean particles size was about 18 nm and the majority of the particles were in the range of 10–22 nm with some big one as large as 40 nm. For double-beam approach, the mean particle size was larger (24.2 nm) and the majority of the particle were distributed from 14 to 35 nm with some big particles can be found with sizes as big as 70 nm. Preliminary measurements of the thermal conductivity and viscosity of the produced samples showed that the thermal conductivity increased about 3–5% and the viscosity increased 3.7% above the base fluid viscosity even with the particle volume concentration as low as 0.01%.     

High-power non-astigmatic TEM<Subscript>00</Subscript> and vortex mode generation in a compact bounce laser design

A novel design of a diode-side-pumped bounce amplifier laser is described that can produce a high-power TEM₀₀ mode and Laguerre–Gaussian (LG) vortex mode operation with high circularity and low astigmatism. The design utilises control of pump size and bounce angle such that the laser mode experiences substantially circular symmetric gain and spherical thermal lensing, in a highly compact fundamental mode resonator. In a simple plane–plane Nd:YVO₄ laser resonator with no other optical components and total length of just 13.4 cm, highly circularised TEM₀₀ operation is produced at wavelength 1064 nm, with 14.2 W of power and high beam quality M ²<1.05. Stable Q-switched TEM₀₀ operation is demonstrated up to 900 kHz and second harmonic power of 7.2 W at 532 nm is generated with conversion efficiency up to 64%. Minor modification of the design to exploit the spherical aberration of the thermal lens is shown to allow for generation of a doughnut-shaped LG vortex mode with average power 16.6 W, maintaining extremely low astigmatism. Q-switched operation of the vortex mode is accomplished up to 400 kHz. A detailed numerical thermal analysis of the amplifier design is performed and gives quantitative agreement with experimental results.     

Investigation of optimum condition in oxygen gas-assisted laser cutting

Laser cutting characteristics including power level and cutting gas pressure are investigated in order to obtain an optimum kerf width. The kerf width is investigated for a laser power range of 50–170 W and a gas pressure of 1–6 bar for steel and mild steel materials. Variation of sample thickness, material type, gas pressure and laser power on the average cut width and slot quality are investigated. Optimum conditions for the steel and mild steel materials with a thickness range of 1–2 mm are obtained. The optimum condition for the steel cutting results in a minimum average kerf width of 0.2 mm at a laser power of 67 W, cutting rate of 7.1 mm/s and an oxygen pressure of 4 bar. A similar investigation for the mild steel cutting results in a minimum average kerf width of 0.3 mm at the same laser power of 67 W, cutting rate of 9.5 mm/s, and an oxygen pressure of 1 bar. The experimental average kerf is about 0.3 mm, which is approximately equal to the estimated focused beam diameter of 0.27 mm for our focusing lens (f=4 cm and 100 W power). This beam size leads to a laser intensity of about 1.74×10⁹ W/m² at the workpiece surface. The estimated cutting rate from theoretical calculation is about 8.07 mm/s (1.0 mm thickness and 100 W power), which agrees with the experimental results that is 7.1 mm/s for 1.0 mm thickness of mild steel at the laser power of 88 W.     

Statistical modeling of laser welding of DP/TRIP steel sheets

In this research work, a statistical analysis of the CO₂ laser beam welding of dual phase (DP600)/transformation induced plasticity (TRIP700) steel sheets was done using response surface methodology. The analysis considered the effect of laser power (2–2.2 kW), welding speed (40–50 mm/s) and focus position (?1 to 0 mm) on the heat input, the weld bead geometry, uniaxial tensile strength, formability limited dome height and welding operation cost. The experimental design was based on Box–Behnken design using linear and quadratic polynomial equations for predicting the mathematical models. The results indicate that the proposed models predict the responses adequately within the limits of welding parameters being used and the welding speed is the most significant parameter during the welding process.     

Synthesis of Mg-Al and Zn-Al-layered double hydroxide nanocrystals using laser ablation in water

In this paper, we report our results on the synthesis of Mg-Al and Zn-Al-layered double hydroxides using the laser ablation in the liquid technique. To prepare these layered double hydroxides (LDH) we first began with the laser generation of a Mg (or zinc) target submerged in deionized water and then ablated an aluminum target submerged in the previously prepared Mg-deionized water suspensions (Mg-dw) to produce Mg-Al LDH and in Zn-dw to prepare Zn-Al LDH. In these ablation tests, the Mg ablation duration was selected to vary from 5 to 60 min, while the Al ablation duration was kept constant at 30 min for all samples. The generated Mg-Al LDH was a gel-like and well crystallized nanoparticles of a rod-like shape and were arranged in a well-organized pattern. When the Mg ablation duration between 25 and 35 min, the synthesized nanocrystals were stoichiometric with a formula of Mg₆Al₂(OH)₁₈4.5(H₂O), the interlayer distance (d_(0 0 3)-spacing) was 7.8 Å and the average grain size was 8.0 nm. The synthesized Zn-Al LDH revealed various lamellar thin plate-like nanostructures of hexagonal morphologies. The average diameters of these structures was about 500 nm and the thickness of a single layer was approximately about 6.0 nm. The XRD diffraction peaks were indexed in hexagonal lattice with a_o=3.07 Å and c_o=15.12 Å. These indexes were (0 0 2), (0 0 4), and (0 0 8) and the corresponding interlayer distances, d-spacing (Å), were 7.56 (0 0 2), 3.782 (0 0 4), and 1.891 (0 0 8), respectively.     

RF behavior of triple-frequency high power fusion gyrotron

The RF behavior of high power, triple frequency (170-, 127.5-, and 85 GHz) gyrotron for fusion application is presented in this paper. The operating mode selection is discussed in detail for each corresponding frequencies and TE_34,10, TE_25,8 and TE_17,5 modes are selected as the operating mode for 170 GHz, 127.5 GHz and 85 GHz operation of the device, respectively. The interaction cavity geometry and beam parameters are finalized by the cold cavity analysis and beam-wave interaction simulations. Considering the beam parameters and the beam launching positions in cavity (beam radius), the design of Magnetically Tunable MIG (MT-MIG) is also presented. Results of MT-MIG confirm the beam launching with desired beam parameters at the beam radius corresponding to the selected operating modes for all three frequencies. The CVD diamond window is also designed for RF power transmission. The beam-wave interaction simulations confirm more than 1 MW power at all three frequencies (170-, 127.5-, and 85 GHz).     

High peak power Nd:YAG laser pumped by 600-W diode laser stack

The Q-switched laser with triangle slab made of Nd:YAG crystal side pumped by 600-W quasi-cw diode laser stack has been designed. The multimode (M²≈2.6) output energy of about 42 mJ was demonstrated in free running mode for110-mJ pump energy. In Q-switch experiments, the KDDP Pockels cell was placed between the slab and rear mirror in plane-plane cavity with output coupler of 84% transmission. The energy of 8 mJ in 2.1-ns pulse duration was obtained for near TEM₀₀ output beam. For passive Q-switching by means of Cr:YAG crystal of 12.6% unsaturated transmission, the energy of 5.1 mJ in 2.5-ns pulse duration was obtained for output beam close to TEM₀₀ mode.     

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 image measurement of twin bubbles formation in shear-thinning fluids

A laser image system for investigating twin bubbles formation in shear-thinning fluid was established. The process of twin-bubble formation could be directly visualized and real-time recorded through computer by means of He–Ne laser as light source using the beam expanding and light amplification technology. The shape and size of bubbles generating in carboxymethylcellulose (CMC) aqueous solutions were studied experimentally at orifice diameter 1 mm, 1.6 mm and 2.4 mm, the orifices interval 1D_o, 2D_o and 3D_o (D_o: orifice diameter) and the gas flow rate from 0.1 to 1.0 ml/s, respectively. The effects of solution mass concentration, orifice diameter and orifice interval on bubble detachment volume were investigated. The results reveals that twin bubbles gradually touch each other and then deviate from the vertical axis crossing the middle point of the line joining the two orifice during the formation process. However compared with the perfect teardrop terminal shapes in glycerol solution, the bubbles formed in CMC solutions are stretched vertically due to the shear-thinning effect of fluids. The bubble detachment volume increases with the solution mass concentration, whereas decreases with orifice diameter. The detachment volume generated at twin orifices is less affected by orifices interval, but still smaller than that at single orifice.     

Femtosecond laser ablation of cadmium tungstate for scintillator arrays

Ultrafast pulsed laser ablation has been investigated as a technique to machine CdWO₄ single crystal scintillator and segment it into small blocks with the aim of fabricating a 2D high energy X-ray imaging array. Cadmium tungstate (CdWO₄) is a brittle transparent scintillator used for the detection of high energy X-rays and γ-rays. A 6 W Yb:KGW Pharos-SP pulsed laser of wavelength 1028 nm was used with a tuneable pulse duration of 10 ps to 190 fs, repetition rate of up to 600 kHz and pulse energies of up to 1 mJ was employed. The effect of varying the pulse duration, pulse energy, pulse overlap and scan pattern on the laser induced damage to the crystals was investigated. A pulse duration of ≥500 fs was found to induce substantial cracking in the material. The laser induced damage was minimised using the following operating parameters: a pulse duration of 190 fs, fluence of 15.3 J cm⁻² and employing a serpentine scan pattern with a normalised pulse overlap of 0.8. The surface of the ablated surfaces was studied using scanning electron microscopy, energy dispersive X-ray spectroscopy, atomic force microscopy and X-ray photoelectron spectroscopy. Ablation products were found to contain cadmium tungstate together with different cadmium and tungsten oxides. These laser ablation products could be removed using an ammonium hydroxide treatment.     

Third-order photonic-crystal distributed-feedback quantum cascade lasers

We demonstrate room-temperature operation of broad-area edge-emitting photonic-crystal distributed-feedback quantum cascade lasers at λ ～ 4.6 μm. The lasers use a weak-index perturbed third-order photonic-crystal lattice to control the optical mode in the wafer plane. Utilizing this coupling mechanism, the near-diffraction-limited beam quality with a far-field profile normal to the facet can be obtained. Single-mode operation with a signal-to-noise ratio of about 20 dB is achieved in the temperature range of 85–290 K. The single-facet output power is above 1 W for a 55 μm × 2.5 mm laser bar at 85 K in pulsed mode.     

AFM study of a SiC film grown on Si(1 0 0) surface using a C2H4 beam

A 3C-silicon carbide (SiC) thin film grown on a Si(1 0 0) surface using an ethylene (C₂H₄) molecular beam has been studied by atomic force microscopy. At the center of the irradiation area of the ethylene beam, the shape of the SiC islands was rectangular, the average length of which was 74.5 nm and the average height was 13.1 nm. Each SiC island consists of the SiC particles with the average diameter of 17 nm. Just inside of the boundary region of the beam irradiation, the average size and height of the islands decreased to 50.1 and 8.2 nm, respectively. Just outside of the boundary region, the average size and height decreased to 17.7 and 5.1 nm, respectively. The average reaction probabilities at the above three points were estimated to be 0.14, 0.27 and 2.7%, respectively. New growth mode of the crystal growth is proposed (particles gathering island mode).     

Patterning of Aluminium thin film on polyethylene terephthalate by multi-beam picosecond laser

High speed patterning of a 30 nm thick Aluminium thin film on a flexible Polyethylene Terephthalate substrate was demonstrated with the aid of Computer Generated Holograms (CGH׳s) applied to a phase only Spatial Light Modulator. Low fluence picosecond laser pulses minimise thermal damage to the sensitive substrate and thus clean, single and multi-beam, front side thin film removal is achieved with good edge quality. Interestingly, rear side ablation shows significant Al film delamination. Measured front and rear side ablation thresholds were F_th=0.20±0.01 J cm⁻² and F_th=0.15±0.01 J cm⁻² respectively. With laser repetition rate of 200 kHz and 8 diffractive spots, a film removal rate of R>0.5 cm² s⁻¹ was demonstrated during patterning with a fixed CGH and 5 W average laser power. The effective laser repetition rate was f_eff~1.3 MHz. The application of 30 stored CGH׳s switching up to 10 Hz was also synchronised with motion control, allowing dynamic large area multi-beam patterning which however, slows micro-fabrication.