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Laser turning with ultra-short laser pulses provides the possibility of manufacturing rotationally symmetric geometries, even of hard to machine materials as fused silica, down to a micrometer scale. In this laser micro machining approach, the laser beam is oriented perpendicularly to the rotational axis and tangentially to the material, whereas the target geometry is realized by moving the constantly rotating specimen according to the specified geometry under the focused laser spot. Due to the fric-tion-less laser ablation it is possible to realize a turning process in fused silica without the use of a contacting tool and therefore without causing mechanical tensions in the work piece. The processing head focuses the laser to a calculated spot size of 18 μm in diameter and the applied processing gas pressure assists in removing the ablated material. In this study, femto-second laser turning of fused silica with a diameter of 3.7 mm is investigated. The influence of the applied pulse energy is stated and the use of a trepanning optic during the turning process is characterized. Furthermore, compre-hensive parameter studies in order to optimize roughness and to find the maximum achievable abla-tion rate are shown. Limited by the mechanical speed of the rotational axis, the highest feasible abla-tion rate is 19.5 mm³/min. A roughness of Ra 0.65 μm are demonstrated.
We report on a comprehensive micromachining study of rotationally symmetric parts using femtosecond laser. A
laser turning process with tangential impingement of the laser radiation complemented by a trepanning optics is
implemented as to accomplish a true laser lathe micromachining approach. With the objective of optimized
ablation rate and reduced surface roughness, the influence of pulse energy, feed rate, trepanning diameter and
angular beam incidence, respectively, is investigated for processing stellite rods. We find the smallest feasible
feature sizes of 8.5 μm in diameter and smoothest surfaces with an arithmetic average of the roughness profile as
low as 0.18 μm. The surface roughness, however, appears to be limited by the occurrence of laser induced periodic
surface structures provoked by the femtosecond laser radiation. Furthermore, the variation of the fluence
in accordance to the incidence on a curved surface is discussed and the heat input into the material is examined
through a longitudinal cross section.
We report on the joining of two different transparent thermoplastic polymers using infrared femtosecond laser pulses. Solely being based on nonlinear absorption, the developed micro-welding process for cyclo-olefin copolymers and polycarbonate does not require any intermediate absorbing layers or any surface pre-processing of the welding partners. In addition, it circumvents any heat damages at the outer surfaces of the welding partners. Femtosecond laser welding of cyclo-olefin copolymers is improved by increasing the numerical aperture of the focusing setup resulting in a wider and more homogenous welding cross-section. Welding results are classified by shear strength and fracture modes are analyzed using scanning electron microscopy. Furthermore, we demonstrate, to the best of our knowledge, first results of ultrashort pulse laser welding of transparent polycarbonate, one of the most used transparent polymers. In view of an optimized and stable micro-welding process, we study the influence of laser power and focal position on welding results. The application of ultrashort pulse laser welding for Lab-on-chip fabrication technologies is demonstrated by sealing an ultrashort pulse laser ablated microfluidic device based on a transparent polymer substrate.
This article discusses the process of the laser turning of rotational symmetric, cylindrical components using ultrashort laser pulses with respect to the geometrical conditions and the resulting energy distribution during the laser turning process. As a result, process predictions and potential process optimizations are feasible. Particular attention is drawn to the laser spot formation on the cylindrical surface of the work piece in conjunction with the positioning of the laser beam relative to the rotation axis of the specimen. Based on fundamental calculations and experimental results, an optimum processing strategy is discussed, whereat the use of a trepanning optic in the laser turning process and the forming of a particular surface structure is additionally being issued.
We report on a comprehensive study of the mechanical properties of maraging steel
body-centred cubic lattice structures fabricated by a hybrid additive manufacturing technology that combines laser powder bed fusion with in situ high-speed milling. As the mechanical properties of additive manufactured components are inferior to, e.g., cast components, surface modifications can improve the mechanical behaviour. Different hybrid additive manufacturing technologies have been designed using additive and subtractive processes, improving process quality. Following this, mechanical testing is performed with respect to static tensile properties and dynamic stress, hardness, and porosity, comparing specimens manufactured by laser powder bed fusion only to those manufactured by the hybrid approach. In addition, the influence of different heat-treatment techniques on the mechanical behaviour of the lattice structures is investigated, namely solution and aging treatment as well as hot isostatic pressing. Thus, the influence of the superior surface quality due to the hybrid approach is evaluated, leading to, e.g., an offset of about 14–16% for the static testing of HIP lattice structures. Furthermore, the dynamic load behaviour can be improved with a finished surface, heading to a shift of the different zones of fatigue behaviour in the testing of hybrid-built specimens.
Axicon generated Bessel beams are a popular tool for high aspect ratio precision laser drilling. Spot diameter and working distance are given by the geometric parameters of the axicon and the wavelength used. Thus, it is difficult to manipulate the beam shape of a Bessel beam for a given setup. Spatial light modulators (SLMs) overcome limitations in flexibility. However, due to the limited phase shift of SLMs, only Bessel beams with flat cone angles and large focal length can be generated. In this contribution, an approach for generating Bessel beams with a shorter, but tunable focal length is presented. A physical axicon was combined with an SLM. A holographic image of a negative axicon is put on the SLM to generate a ring beam, which is focused by a subsequent physical axicon to get a small focal diameter. Thus, different sized high aspect ratio micro holes can be drilled without using any moving components.
We report on laser drilling borehole arrays using ultrashort pulsed lasers with a particular focus on reducing the inadvertent heat accumulation across the workpiece by optimizing the drilling sequence. For the optimization, evolutionary algorithms are used and their results are verified by thermal simulation using Comsol and experimentally evaluated using a thermal imaging camera. To enhance process efficiency in terms of boreholes drilled per second, multi-spot approaches are employed using a spatial light modulator. However, as higher temperatures occur across the workpiece when using simultaneous multi-spot drilling as compared to a single-spot process, a subtle spatial distribution and sequence of the multi-spot approach has to be selected in order to limit the
resulting local heat input over the processing time. Different optimization approaches based on evolutionary algorithms aid to select those drilling sequences which allow for the combination of a high efficiency of multi-spot profiles, a low-generated process temperature and a high-component quality. In particular, using a 4 x 4 laser spot array allows for the drilling of 40,000 boreholes in less than 76 s (526 boreholes/s) with a reduced temperature increase by about 35%, as compared to a single spot process when employing an optimized drilling sequence.
Multi-Bessel Beams Generated by an Axicon and a Spatial Light Modulator for Drilling Applications
(2023)
We report on an optical setup to generate multi-Bessel beam profiles combining a refractive axicon and a spatial light modulator. Based on their particular beam profile, Bessel beams offer advantageous properties for micro drilling processes and internal volume processing, especially for transparent materials. In addition, the laser power of industrial, ultrashort pulsed lasers has increased significantly over the last few years, offering the possibility for highly efficient processes using multi-spot profiles. Our optical concept combines the dynamic possibilities of beam splitting using a spatial light modulator with the benefits of Bessel beams, which facilitates multi-Bessel beam processing. Beside the simulation and experimental evaluation of the generated multi-Bessel beams, we exemplify the applicability of the developed module for the perforation of thin metal foils by micro drilling.