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.     

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.     

Investigating the CO2 laser cutting parameters of MDF wood composite material

Laser cutting of medium density fibreboard (MDF) is a complicated process and the selection of the process parameters combinations is essential to get the highest quality cut section. This paper presents a means for selecting the process parameters for laser cutting of MDF based on the design of experiments (DOE) approach. A CO₂ laser was used to cut three thicknesses, 4, 6 and 9 mm, of MDF panels. The process factors investigated are: laser power, cutting speed, air pressure and focal point position. In this work, cutting quality was evaluated by measuring the upper kerf width, the lower kerf width, the ratio between the upper kerf width to the lower kerf width, the cut section roughness and the operating cost. The effect of each factor on the quality measures was determined. The optimal cutting combinations were presented in favours of high quality process output and in favours of low cutting cost.     

Optimal ablation of fluorine-doped tin oxide (FTO) thin film layers adopting a simple pulsed Nd:YAG laser with TEM00 mode

In material processing, a laser system with optimal laser parameters has been considered to be significant. Especially, the laser ablation technology is thought to be very important for fabricating a dye-sensitized solar cell (DSSC) module with good quality. Moreover, the TEM₀₀ mode laser beam is the most dominant factor to decide the incident photon to current conversion efficiency (IPCE) characteristics. In order to get the TEM₀₀ mode, a pin-hole is inserted within a simple pulsed Nd:YAG laser resonator. And the spatial field distribution is measured by using three pin-hole diameters of 1.6, 2.0 and 4.0 mm, respectively. At that moment, each case has the same laser beam energy by adjusting the discharge voltage and pulse per second (pps). From those results, it is known that the pin-hole size of 1.6 mm has the perfect TEM₀₀ mode. In addition, at the charging voltage of 1000 V, 10 pps, the feeding speed of 6.08 mm/s and the overlapping rate (OL) of 62%, the scanning electron microscope (SEM) photograph of fluorine-doped tin oxide (FTO) thin film layers shows the best ablation trace.     

Micro-machining of silicon wafer in air and under water

Laser ablation micro-machining tests are conducted on silicon wafer, both in air and under flowing water stream, with the use of 355 nm-X AVIA laser. Effects of laser pulse frequency, power level, scan velocity and focal plane position on the associated laser spatter deposition (in air), irradiated areas (under flowing water film) and taper are investigated. It shows that low frequency, i.e. 30–40 kHz, and high peak power result in smaller spatter and irradiated areas, and the hole taper decreases with increase in pulse frequency. Increase in the laser fluence broadens both the areas and increases the hole taper. Both areas enlarge with the increase of scanning velocity of more than 3 mm s^?1. The scan velocity has no effect on hole taper in air environment but inconsistent hole taper is obtained under flowing water stream. Furthermore, moving the focal plane position below the workpiece surface contributes relatively smaller areas of spatter deposition, irradiation and taper in comparison to zero focal plane position. Finally, the differences between laser ablation in air and under water are identified. The reduction in the spatter deposition and irradiated areas around the perimeter of the ablated hole and a smaller taper with the use of laser trepan drilling method in air and under water machining are investigated in this paper.     

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.     

A method for rapid measurement of laser ablation rate of hard dental tissue

The aim of the study reported here is the development of a new method which allows rapid and accurate in-vitro measurements of three-dimensional (3D) shape of laser ablated craters in hard dental tissues and the determination of crater volume, ablation rate and speed. The method is based on the optical triangulation principle. A laser sheet projector illuminates the surface of a tooth, mounted on a linear translation stage. As the tooth is moved by the translation stage a fast digital video camera captures series of images of the illuminated surface. The images are analyzed to determine a 3D model of the surface. Custom software is employed to analyze the 3D model and to determine the volume of the ablated craters. Key characteristics of the method are discussed as well as some practical aspects pertinent to its use. The method has been employed in an in-vitro study to examine the ablation rates and speeds of the two main laser types currently employed in dentistry, Er:YAG and Er,Cr:YSGG. Ten samples of extracted human molar teeth were irradiated with laser pulse energies from 80 mJ to the maximum available energy (970 mJ with the Er:YAG, and 260 mJ with the Er,Cr:YSGG). About 2000 images of each ablated tooth surface have been acquired along a translation range of 10 mm, taking about 10 s and providing close to 1 million surface measurement points. Volumes of 170 ablated craters (half of them in dentine and the other half in enamel) were determined from this data and used to examine the ablated volume per pulse energy and ablation speed. The results show that, under the same conditions, the ablated volume per pulse energy achieved by the Er:YAG laser exceeds that of the Er,Cr:YSGG laser in almost all regimes for dentine and enamel. The maximum Er:YAG laser ablation speeds (1.2 mm³/s in dentine and 0.7 mm³/s in enamel) exceed those obtained by the Er,Cr:YSGG laser (0.39 mm³/s in dentine and 0.12 mm³/s in enamel). Since the presented method proves to be easy to use and allows quite rapid measurements it may become a valuable tool to study the influence of various laser parameters on the outcome of laser ablation of dental tissues.     

Surface treatment of CFRP composites using femtosecond laser radiation

In the present work, we investigate the surface treatment of carbon fiber-reinforced polymer (CFRP) composites by laser ablation with femtosecond laser radiation. For this purpose, unidirectional carbon fiber-reinforced epoxy matrix composites were treated with femtosecond laser pulses of 1024 nm wavelength and 550 fs duration. Laser tracks were inscribed on the material surface using pulse energies and scanning speeds in the range 0.1–0.5 mJ and 0.1–5 mm/s, respectively. The morphology of the laser treated surfaces was investigated by field emission scanning electron microscopy. We show that, by using the appropriate processing parameters, a selective removal of the epoxy resin can be achieved, leaving the carbon fibers exposed. In addition, sub-micron laser induced periodic surface structures (LIPSS) are created on the carbon fibers surface, which may be potentially beneficial for the improvement of the fiber to matrix adhesion in adhesive bonds between CFRP parts.     

Experimental femtosecond laser photodisruption of rabbit sclera for minimally invasive laser sclerostomy: An in vitro study

Femtosecond laser technology, used as a minimally invasive tool in intrastromal refractive surgery, may also have potential as a useful instrument for glaucoma filtration surgery. The purpose of the present study was to evaluate the feasibility of minimally invasive laser sclerostomy by femtosecond laser photodisruption and seek the appropriate patterns of laser ablation and relevant laser parameters. A femtosecond laser (800 nm/50 fs/1 kHz), focused by a 0.1 numerical aperture (NA) objective lens, with different pulse energies and exposure times was applied to ablate hydrated rabbit sclera in vitro. The irradiated samples were examined by scanning electron microscopy (SEM). By moving a three-dimensional, computer-controlled translation stage to which the sample was attached, the femtosecond laser could produce three types of ablation patterns, including linear ablation, cylindrical aperture and rectangular cavity. With pulse energies ranging from 37.5 to 150 μJ, the linear lesions were consistently observed at the inner surface of sclera, whereas it failed to make any photodisruption if pulse energy was below the threshold value of 31.25 μJ, with the corresponding threshold intensity of 4.06×10¹⁴ W/cm². The depths of the linear lesions increased linearly with both pulse energy (37.5–150 μJ) and exposure time (0.1–0.4 s). Histological examination showed the incisions produced by femtosecond laser photodisruption had precise geometry and the edges were sharp and smooth, with no evidence of collateral damage to the surrounding tissue. Our results predict the potential application of femtosecond laser pulses in minimally invasive laser sclerostomy for glaucoma treatment.     

Modeling and optimization on Nd:YAG laser turned micro-grooving of cylindrical ceramic material

Nd:YAG laser turning is a new technique for manufacturing micro-grooves on cylindrical surface of ceramic materials needed for the present day precision industries. The importance of laser turning has directed the researchers to search how accurately micro-grooves can be obtained in cylindrical parts. In this paper, laser turning process parameters have been determined for producing square micro-grooves on cylindrical surface. The experiments have been performed based on the statistical five level central composite design techniques. The effects of laser turning process parameters i.e. lamp current, pulse frequency, pulse width, cutting speed (revolution per minute, rpm) and assist gas pressure on the quality of the laser turned micro-grooves have been studied. A predictive model for laser turning process parameters is created using a feed-forward artificial neural network (ANN) technique utilized the experimental observation data based on response surface methodology (RSM). The optimization problem has been constructed based on RSM and solved using multi-objective genetic algorithm (GA). The neural network coupled with genetic algorithm can be effectively utilized to find the optimum parameter value for a specific laser micro-turning condition in ceramic materials. The optimal process parameter settings are found as lamp current of 19 A, pulse frequency of 3.2 kHz, pulse width of 6% duty cycle, cutting speed as 22 rpm and assist air pressure of 0.13 N/mm² for achieving the predicted minimum deviation of upper width of ?0.0101 mm, lower width 0.0098 mm and depth ?0.0069 mm of laser turned micro-grooves.     

Microhardness of a dental restorative composite resin containing nanoparticles polymerized with argon ion laser

The objective of this study was to compare the microhardness of two resin composites (microhybrid and nanoparticles). Light activation was performed with argon ion laser 1.56 J (L) and halogen light 2.6 J (H) was used as control. Measurements were taken on the irradiated surfaces and those opposite them, at thicknesses of 1, 2 and 3 mm. To evaluate the quality of polymerization, the percentages of maximum hardness were calculated (PMH). For statistical analysis the ANOVA and Tukey tests were used (p ≤ 0.05). To microhybrid was shown that the hardness with laser was inferior to the hardness achieved with halogen light, for both the 1 mm and 2 mm. The nanoparticles polymerized with laser, presented lower hardness even on the irradiated surface, than the same surface light activated with halogen light. The microhybrid attained a minimum PMH of 80% up to the thickness of 2 mm with halogen light, and with laser, only up to 1 mm. The nanoparticles attained a minimum PMH of 80% up to 3 mm thickness with halogen light and with laser this minimum was not obtained at any thickness. Based on these results, it could be concluded that light activation with argon ion laser is contra-indicated for the studied nanoparticles.     

An experimental study of an acousto-optic Q-switched Yb3+-doped all-fiber laser

The Q-switched fiber lasers are very attractive sources in many applications such as military affairs, surgical operation, laser machining, laser marking, nonlinear frequency conversion, range finding, remote sensing and optical time domain reflectometer. In this paper, an acousto-optic Q-switched Yb³⁺-doped all-fiber laser at 1083 nm is reported. The pulse energy of 2.94 mJ has been obtained at the pump power of 8.47 W, and the pulse width is 3 μs.     

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.     

High-power sixth-harmonic generation of an Nd:YAG laser with KBe2BO3F2 prism-coupled devices

High-power sixth harmonic generation from an Nd:YAG laser (10 ns, 10 kHz) has been achieved with a KBe₂BO₃F₂ (KBBF) prism-coupled device (PCD) containing a 1.95 mm thick KBBF crystal. The highest output power reached 120.5 mW at 177.3 nm, and the highest conversion efficiency from 354.7 to 177.3 nm was 1.82%. Moreover, stable sixth harmonic output with an average power of 22.2 mW was produced by another KBBF-PCD, in which the thickness of the KBBF crystal was 1.51 mm. The highest and stable sixth harmonic output powers are improved by about three and six times compared with the previously published results, respectively.     

Laser ablation fast pulse discharge plasma spectroscopy analysis of Pb,Mg and Sn in soil

Laser ablation fast pulse discharge plasma spectroscopy (LA-FPDPS) technique is a recently developed atomic emission analytical technique that is analogous to dual pulse laser induced breakdown spectroscopy (DP-LIBS). LA-FPDPS, however, uses a periodical oscillating discharge plasma generation method on samples instead of the second laser beam in DP-LIBS. Here we describe the electric characteristics and its application to the analysis of Pb, Mg and Sn in soil. Due to the fast discharge process, the peak power deposition rate is up to 1.5 MW, although the discharge energy is relatively small. The main energy deposition process only last for ~ 4 μs. From the measured spectra, calibration curves for Pb, Mg and Sn in soil were derived and the limits of detection were 1.5 μg/g, 34 μg/g and 0.16 μg/g respectively.     

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%.     

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.     

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.     

Experimental proof on two-cone axisymmetric-folded combination CO2 laser

The experimental proof of the light output on the two-cone axisymmetric-folded combination (ASFC) CO₂ laser has been performed. The output power from the centre discharge tube is 26.7 W, and that of one couple of folded discharge tubes is 40.5 W. Seventeen beams can be obtained from the device, which are from the folded cavities with axes placed in the inner and outer cones, respectively. Therefore, the ASFC CO₂ laser with more discharge tubes can be fabricated and much higher output power can be obtained.     

A diode end-pumped passively Q-switched Nd:YAG/KTA Raman laser

A diode end-pumped passively Q-switched Nd:YAG/KTA intracavity Raman laser is presented. A KTA crystal with a size of 5 mm × 5 mm × 25 mm is used as the Raman active medium and its 234 cm^?1 Raman mode is employed to finish the conversion from 1064 nm fundamental laser to 1091 nm Raman laser. A 2 mm thick Cr⁴⁺:YAG crystal is used as the saturable absorber. With an LD pump power of 7.5 W, the first-Stokes power of 250 mW is obtained with a pulse repetition frequency of 14.5 kHz. The corresponding diode-to-Stokes conversion efficiency is 3.3% and the pulse energy is 17.2 μJ. Pulse width is measured to be 12.6 ns and peak power is 1.4 kW.