Laser interference metallurgy: A new method for periodic surface microstructure design on multilayered metallic thin films

Methods for micro- and nanostructuring are essential for functionalization of materials surfaces. In particular, photon-assisted methods for synthesis of functional surfaces have been intensively investigated in the last years. In this study, a new method for surface modification and production of long-range order periodical structures called “laser interference metallurgy” is explored. A metallic thin film sample consisting of three layers composed of Fe, Cu and Al (from top to bottom) on a glass substrate was irradiated with an interference pattern using a Nd:YAG laser (wavelength of 355 nm, 10 ns of pulse duration). For the interference pattern, a configuration producing a line-type energy distribution was chosen. The laser fluence was high enough to melt the aluminium and copper layers at the interference maxima but the iron layer remained in the solid state. Thus, diffusive and convective exchange occurred between aluminium and copper at the energy maxima positions leading to periodical alloy formation with a long-range order. Because it remained in solid state, the iron layer at the top acted as a protective layer effectively preventing removal of the molten layers. The interaction of the different layers was characterized using FIB, TEM and EDX in STEM mode.