Multi-objective optimization of laser cutting for flash memory modules with special shapes using grey relational analysis

This paper presents a novel effective method for optimizing laser cutting of specially shaped electronic printed circuit board (PCB) carrier substrates of advanced integrated circuit (IC) back-end packages that have multiple performance characteristics identified using grey relational analysis (GRA). Laser cutting parameters, including laser beam parameters (average laser power and Q-switch frequency), focusing parameters (laser beam focusing spot size), and machine parameters (laser cutting speed), were optimized based on multiple performance characteristics. Some characteristics of the specially shaped flash memory module for IC packages, such as smart disk (SD) cards are verified. The characteristics of interest are the average surface roughness on a PCB substrate cross-section, and the maximum width of the heat-affected zone (HAZ). Eight experiments were conducted using GRA to optimize the settings for laser beam cutting parameters to generate various quality characteristics. Analysis of the grey relational grade indicates that parameter significance and the optimal parameter combination for the laser cutting process are identified. The analytical results from two confirmation experiments using the optimal parameters confirm that laser cutting technology can be effectively applied to cut substrates into special shapes.     

Use of the grey relational analysis to determine optimum laser cutting parameters with multi-performance characteristics

This paper presents an effective approach for the optimization of laser cutting process of St-37 steel with multiple performance characteristics based on the grey relational analysis. Sixteen experimental runs based on the Taguchi method of orthogonal arrays were performed to determine the best factor level condition. The response table and response graph for each level of the machining parameters were obtained from the grey relational grade. In this study, the laser cutting parameters such as laser power and cutting speed are optimized with consideration of multiple-performance characteristics, such as workpiece surface roughness, top kerf width and width of heat affected zone (HAZ). By analyzing the grey relational grade, it is observed that the laser power has more effect on responses rather than cutting speed. It is clearly shown that the above performance characteristics in laser cutting process can be improved effectively through this approach.     

Multi-objective optimization of Nd:YAG laser cutting of thin superalloy sheet using grey relational analysis with entropy measurement

This paper presents a hybrid optimization approach for the determination of the optimum laser cutting process parameters which minimize the kerf width, kerf taper, and kerf deviation together during pulsed Nd:YAG laser cutting of a thin sheet of nickel-based superalloy SUPERNI 718 (an equivalent grade to Inconel 718). A hybrid approach of Taguchi methodology and grey relational analysis has been applied to achieve better cut qualities within existing resources. The input process parameters considered are oxygen pressure, pulse width, pulse frequency, and cutting speed. A higher resolution based L₂₇ orthogonal array has been used for conducting the experiments for both straight and curved cut profiles. The designed experimental results are used in grey relational analysis and the weights of the quality characteristics are determined by employing the entropy measurement method. The significant parameters were obtained by performing analysis of variance (ANOVA). The optimized parameters for straight and curved laser cut profiles have been compared. On the basis of optimization results it has been found that the optimal parameter level suggested for straight cut profiles are not valid for curved cut profiles. The application of the hybrid approach for straight cuts has reduced K_t and K_d by 52.37% and 17%, respectively. For curved cuts the approach has reduced K_w and K_t by 8.45% and 44.44%, respectively. The results have also been verified by running confirmation tests.     

Laser fluence, repetition rate and pulse duration effects on paint ablation

The efficiency (mm³/(J pulse)) of laser ablation of paint was investigated with nanosecond pulsed Nd:YAG lasers (λ = 532 nm) as a function of the following laser beam parameters: pulse repetition rate (1-10,000 Hz), laser fluence (0.1-5 J/cm²) and pulse duration (5 ns and 100 ns). In our study, the best ablation efficiency (η ≅ 0.3 mm³/J) was obtained with the highest repetition rate (10 kHz) at the fluence F = 1.5 J/cm². This ablation efficiency can be associated with heat accumulation at high repetition rate, which leads to the ablation threshold decrease. Despite the low thermal diffusivity and the low optical absorption of the paint (thermal confinement regime), the ablation threshold fluence was found to depend on the pulse duration. At high laser fluence, the ablation efficiency was lower for 5 ns pulse duration than for the one of 100 ns. This difference in efficiency is probably due to a high absorption of the laser beam by the ejected matter or the plasma at high laser intensity. Accumulation of particles at high repetition rate laser ablation and surface shielding was studied by high speed imaging.     

Effects of laser operating parameters on metals micromachining with ultrafast lasers

180 femtoseconds (1 kHz) and 10 picoseconds (1-50 kHz) ultrafast laser micro-structuring of the metals Ti alloy, Al and Cu have been studied for the purpose of industrial application. The effects of some key laser operating parameters were investigated. The evolution of surface morphology revealed that laser pulses overlap in a range around the spatial FWHM can help to achieve optimal residual surface roughness. While observed ablation rate (unit: μm³ per pulse) changed dramatically with repetition rate due to the combined effects of plasma absorption, residual thermal energy and phase transition, higher throughput can be achieved with higher repetition rate. This study also indicated that residual surface roughness is almost independent of repetition rate at 10 ps temporal pulse length. The ablation depth is approximately proportional to the number of overscan; however, machining accuracy deteriorates, especially for femtosecond laser processing and metals with low thermal conductivity and short electron-phonon coupling time.     

Modelling and optimization of cut quality during pulsed Nd:YAG laser cutting of thin Al-alloy sheet for straight profile

Thin sheets of aluminium alloys are widely used in aerospace and automotive industries for specific applications. Nd:YAG laser beam cutting is one of the most promising sheetmetal cutting process for cutting sheets for any profile. Al-alloy sheets are difficult to cut by laser beam because of its highly reflective nature. This paper presents modelling and optimization of cut quality during pulsed Nd:YAG laser cutting of thin Al-alloy sheet for straight profile. In the present study, four input process parameters such as oxygen pressure, pulse width, pulse frequency, and cutting speed and two output parameters such as average kerf taper (T_a) and average surface roughness (R_a) are considered. The hybrid approach comprising of Taguchi methodology (TM) and response surface methodology (RSM) is used for modelling whereas multi-objective optimization is performed using hybrid approach of TM and grey relational analysis (GRA) coupled with entropy measurement methodology. The entropy measurement methodology is employed for the calculation of weight corresponding to each quality characteristic. The results indicate that the hybrid approaches applied for modelling and optimization of the LBC process are reasonable.     

Multi-performance characterization analysis of diameter and taper angle on alumina ceramic via using pulsed ultraviolet laser percussion drilling method

This paper presents the optimal conditions for the ultraviolet laser percussion drilling of alumina materials intended for use in heat sinks. The Taguchi method and grey relational analysis, along with the consideration of multiple quality characteristics, were applied for determining the optimal parameters. The entrance diameter and taper angle of the drilled hole were affected by the material processing parameters, including laser power, pulse duration, focal plane position, and number of pulses. The Taguchi method and grey relational analysis were used for assessing the effects of the operational parameters on multiple performance characteristics. Nine experiments based on an orthogonal array were performed. According to the results, the optimal process parameters were as follows: laser energy density, 3.82 J/cm²; focal plane position, 0.1 mm; number of pulses, 20 shots; and single pulse duration, 3 ms. Analysis of the grey relational grade revealed that the focal plane position was the most dominant parameter.     

Electro-optic Q-switched intracavity optical parametric oscillator at 1.53 μm based on KTiOAsO4

An eye-safe, high peak power optical parameter oscillator (OPO) intracavity pumped by electro-optic Q-switched Nd:YAG laser is presented. This OPO is based on a 20 mm length KTiOAsO₄ crystal with non-critical phase matching (θ = 90°, ?=0°) cut. An aperture ∅3 mm acted as limiting diaphragm to get good beam quality of pumping laser. The output energy of 25 mJ at the signal wavelength 1.53 μm was obtained with repetition rate of 1 Hz. The highest peak power intensity was up to 88 MW/cm² with pulse width of 4 ns. Without diaphragm, the maximum output energy of 90 mJ was achieved with area of light spot (∅6 mm) four times larger, but the peak power intensity was lower.     

Growth of Ga-doped ZnO films with ZnO buffer layer by sputtering at room temperature

Gallium-doped zinc oxide films have been grown on glass substrates with and without ZnO buffer layers by r.f. magnetron sputtering at room temperature. In this approach, the grey relational Taguchi method analysis is adopted to solve the coating process with multiple deposition qualities. Optimal coating parameters can then be determined by using the gray relational grade as a performance index. The GZO coating parameters (r.f. power, sputtering pressure, O₂/(Ar+O₂) flow-rate ratios, and deposition time) are optimized, by taking into account the multiple performance characteristics (structural, morphological, deposition rate, electrical resistivity, and optical transmittance). The results indicate that with the grey relational Taguchi method, the electrical resistivity of GZO films is reduced from 9.23×10⁻³ to 5.77×10⁻³ Ω cm and optical transmittance increases from 79.42% to 82.95%, respectively. The ZnO buffer layer can reduce the electrical resistivity of GZO films from 5.77×10⁻³ to 2.38×10⁻³ Ω cm. It can be anticipated that room temperature deposition enables film deposition onto polymeric substrates for flexible optoelectronic devices.     

Multiple-objective optimization in precision laser cutting of different thermoplastics

Thermoplastics are increasingly being used in biomedical, automotive and electronics industries due to their excellent physical and chemical properties. Due to the localized and non-contact process, use of lasers for cutting could result in precise cut with small heat-affected zone (HAZ). Precision laser cutting involving various materials is important in high-volume manufacturing processes to minimize operational cost, error reduction and improve product quality. This study uses grey relational analysis to determine a single optimized set of cutting parameters for three different thermoplastics. The set of the optimized processing parameters is determined based on the highest relational grade and was found at low laser power (200 W), high cutting speed (0.4 m/min) and low compressed air pressure (2.5 bar). The result matches with the objective set in the present study. Analysis of variance (ANOVA) is then carried out to ascertain the relative influence of process parameters on the cutting characteristics. It was found that the laser power has dominant effect on HAZ for all thermoplastics.     

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.     

Low temperature ITO thin film deposition on PES substrate using pulse magnetron sputtering

Experiments were conducted using pulse magnetron sputtering (PMS) to deposit transparent conducting indium tin oxide (ITO) thin film onto flexible polyethersulfone (PES) plastic substrates. The thin film microstructure, optoelectronic and residual stress were analyzed using the modulating PMS power, work pressure, pulse frequency, duty cycle and cycle time process parameters. The residual stress of the thin film was determined by scanning electron microscopy (SEM) combined with the Sony equation. The experimental results show that PMS has a lower process temperature, higher deposition rate and lower resistivity compared with the radio frequency process at the same output power. The duty cycle increase produces the optimum optoelectronic characteristics. When the pressure, power, duty cycle and sputter time are increased, the thin film stress will also increase, causing flexural distortion in the PES plastic substrate. When the deposition thickness reaches 1.5 μm, ITO thin film will appear with a distinct split. Under 5 mtorr work pressure, 60 W power, 33 μs duty time and 2 μs pulse reverse time at duty cycle 95%, thin film with an optimized electrical 3.0 × 10⁻⁴ Ω-cm, RMS surface roughness of 0.85 nm and visible region optical transmittance will be achieved with acquisition of over 85%.     

Laser etching of transparent materials at a backside surface adsorbed layer

The laser etching using a surface adsorbed layer (LESAL) is a new method for precise etching of transparent materials with pulsed UV-laser beams. The influence of the processing parameters to the etch rate and the surface roughness for etching of fused silica, quartz, sapphire, and magnesium fluoride (MgF₂) is investigated. Low etch rates of 1 nm/pulse and low roughness of about 1 nm rms were found for fused silica and quartz. This is an indication that different structural modifications of the material do not affect the etching significantly as long as the physical properties are not changed. MgF₂ and sapphire feature a principal different etch behavior with a higher etch rate and a higher roughness. Both incubation effects as well as the temperature dependence of the etch rate can be interpreted by the formation of a modified near surface region due to the laser irradiation. At repetition rates up to 100 Hz, no changes of the etch rate have been observed at moderate laser fluences.     

Laser direct patterning of the T-shaped ITO electrode for high-efficiency alternative current plasma display panels

The laser direct patterning technique is one of the new methods of direct etching process to replace the conventional photolithography. In this experiment, a Q-switched diode-pumped Nd:YVO₄ (λ = 1064 nm) laser was used to produce the indium-tin oxide (ITO) patterns with a complex T-shaped structure on glass substrate. The results showed that the overlapping rate of laser beam had a major effect on the quality of the edge of the ITO electrode. When the overlapping rate was about 75%, it was possible to obtain optimum linearity in the edge of patterned ITO electrode. By using the optimum conditions of 75% overlapping rate, 500 mm/s scanning speed, and 40 kHz repetition rate, an alternative current plasma display panels (AC PDPs) with T-shaped ITO electrode was fabricated and characterized. The discharging results showed that the AC PDPs with the laser ablated T-shaped ITO electrode had a better discharging characteristics compared to the conventional sample with wet-etched stripe-type ITO electrode.     

Surface roughness analysis and improvement of PMMA-based microfluidic chip chambers by CO2 laser cutting

For the microfluidic chip, the surface roughness of the chamber sidewall is an important parameter in estimating its quality. In this work, the chambers of the polymethyl methacrylate (PMMA)-based microfluidic chip were fabricated by CO₂ laser cutting, and then the surface roughness of the sections cut using different laser parameters and ambient temperature was studied by a non-contact 3D surface profiler. Our observation shows that the surface roughness results primarily from the residues on the laser-cut edge, which are produced by the bubbles bursting. To reduce the surface roughness of the cut section, a new approach is proposed, that is preheating the PMMA sheet to a suitable ambient temperature during laser processing. The results indicate that at a preheat temperature of 70-90 °C, the surface roughness resulting from the cut would be reduced. In our experiment, the best result was that the arithmetical mean roughness is R_a = 100.86 nm when the PMMA sheet was heated to 85 °C.     

678 nm RTP electro-optical Q-switched ceramic laser

The RTP electro-optical Q-switched ceramic laser at the wavelength of 678 nm with narrow pulse width is studied. We used the laser diode arrays side-pumped Nd:YAG ceramic crystal with 1.1 at% Nd doping and dimensions of Φ3 mm × 50 mm, designed folding cavity parameters, and discussed the variation of the beam radius in the ceramic crystal and frequency doubling crystal with the thermal focal length of ceramic crystal or KTP crystal. By using double RTP crystals as electro-optic Q-switch and KTP crystal type II phase matching for intracavity frequency-doubling, a narrow pulse width electro-optical Q-switched Nd:YAG ceramic laser was obtained. The output energy of 0.9 mJ and the pulse width of 41.6 ns at 678 nm are obtained at the repetition rate of 1000 Hz and pumped power of 144 W. The results formed the basis for the further development of the high power and high efficiency ceramic red laser.     

High performance wavelength-swept laser with mode-locking technique for optical coherence tomography

We demonstrate a Fourier-domain mode-locked wavelength-swept laser that uses a polygon-based narrowband optical scanning filter and a high-efficiency semiconductor optical amplifier. Peak and average output powers of 98 mW and 71 mW have been achieved, respectively, without an external amplifier, while the wavelength was swept continuously from 1247 nm to 1360 nm. A unidirectional wavelength sweeping rate of 7452 nm/ms (65.95 kHz repetition rate) was achieved by using a 72 facet polygon scanner with a rotation rate of 916 revolutions per second. The instantaneous linewidth of this laser is 0.09 nm, which corresponds to a coherence length of 16 mm. This laser is most suitable for optical coherence tomography applications.     

Pulsed inductive discharge CO2 laser

A pulsed inductive discharge CO₂ laser with a wavelength of 10.6 μm has been created for the first time. The excitation system of a cylindrical pulsed inductive discharge (pulsed inductively coupled plasma) in the gas mixture of CO₂:N₂:He was developed. The temporal and energy parameters of the laser radiation were investigated. The maximum inductive discharge CO₂ laser radiation energy of 104 mJ was achieved. An average power of 3.2 W was obtained at laser generation energy of 65 mJ and pulse repetition rate of 50 Hz. In the cross-section, the laser radiation had the ring shape with an external diameter of 34 mm and thickness of 4-5 mm. The measured divergence of laser radiation was 12 mrad.     

Cleaved end-face quality of microstructured polymer optical fibres

The cutting of a microstructured polymer optical fibre to form an optical end-face is studied. The effect of the temperature and speed of the cutting blade on the end-face is qualitatively assessed and it is found that for fibres at temperatures in the range 70-90 °C, a blade at a similar temperature moving at a speed of less than 0.5 mm/s produces a good quality end-face. The nature of the damage caused by the cutting process was examined and found to vary with fibre temperature, blade quality and cut depth. Thermo-mechanical analysis showed that the drawn material was significantly more visco-elastic than the annealed raw material in the 70-90 °C temperature range. The behaviour of the surface damage with cut depth was found to be consistent with the behaviour of a visco-elastic material.     

Effects of processing parameters on laser cutting of aluminium-copper alloys using off-axial supersonic nozzles

Conventional laser cutting involves the utilization of converging coaxial nozzles to inject the assist gas used to remove the molten material. This processing system prevents the utilization of this technique to cut aluminium alloys for aerospace applications. The inefficient removal of molten material by the assist gas produces cuts with poor quality; very rough cuts, with a large amount of dross, and a large heat affected zone (HAZ) are obtained. An alternative to increase the assist gas performance is the utilization of off-axial supersonic nozzles. Removal of molten material is substantially increased and cuts with high quality are obtained. On the other hand, pulsed laser cutting offers superior results during the processing of high reflectivity materials as aluminium alloys. However, there are no experimental studies which explore the pulsed laser cutting of aluminium alloys by means of a cutting head assisted by an off-axis supersonic nozzle.The present work constitutes a quantitative experimental study to determine the influence of processing parameters on the cutting speed and quality criteria during processing by means of off-axial supersonic nozzles. Cutting experiments were performed in pulsed mode and the results explained under the basis of the molten material removal mechanisms. Performed experiments indicate a reduction in cutting speed as compared to continuous wave (CW) mode processing and the existence of two processing regimes as a function of the pulse frequency. Best results are obtained under the high pulse frequency one (f > 100 Hz) because the superior capabilities of molten material removal of the supersonic jets are completely exploited in this processing regime.