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Ultrafast Laser-Based Manufacturing

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (31 December 2016) | Viewed by 52623

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Assoc. Prof. Dr. Martin Byung-Guk Jun

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Department of Mechanical Engineering, University of Victoria, Victoria, BC, Canada
Special Issues, Collections and Topics in MDPI journals

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Dear Colleagues,

Ultrafast laser-based material processing or manufacturing has shown promise for many industrial applications. Ultrafast lasers have extremely short pulses but with high peak powers, and allow precise processing of materials at the focal point, minimizing the laser influence on the surrounding area. Thus, with ultrafast lasers, material removal is through vaporization instead of melting, and precise processing becomes possible on a wide range of materials, including metals, ceramics, semiconductors, transparent materials, fiber-reinforced materials, and composite structures. Due to its attractive attributes, ultrafast laser-based manufacturing is being utilized in consumer electronics, photonics, medial, aerospace, and automotive industries. The recent advent of high average power ultrafast lasers has potential to take laser material processing to a new level. Therefore, we are announcing a Special Issue on “Ultrafast Laser-Based Manufacturing” and invite original contributions to capture the current state of research related to material processing and manufacturing technologies. The scope of this issue covers, but is not limited to, understanding, modeling, monitoring, and control of the process, material behaviors during ultrafast laser ablation or refractive index modifications, process condition optimization, surface texturing or functionalization, developments of sensors and devices using ultrafast lasers, product innovations, and applications.

We are pleased to invite you to submit manuscripts for this Special Issue on “Ultrafast Laser-Based Manufacturing” in the form of full research papers, communications, and review articles. We look forward to receiving your contributions to this Special Issue.

Prof. Dr. Martin Byung-Guk Jun
Guest Editor

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Keywords

ultrafast laser
femtosecond
picosecond
material processing
micromachining
photonics
laser-assisted manufacturing
surface texturing
refractive index modification
sensors

Published Papers (7 papers)

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Research

1118 KiB

Open AccessArticle

Crystallinity and Sub-Band Gap Absorption of Femtosecond-Laser Hyperdoped Silicon Formed in Different N-Containing Gas Mixtures

by Haibin Sun, Jiamin Xiao, Suwan Zhu, Yue Hu, Guojin Feng, Jun Zhuang and Li Zhao

Materials 2017, 10(4), 351; https://doi.org/10.3390/ma10040351 - 28 Mar 2017

Cited by 8 | Viewed by 4109

Abstract

Femtosecond (fs)-laser hyperdoped silicon has aroused great interest for applications in infrared photodetectors due to its special properties. Crystallinity and optical absorption influenced by co-hyperdoped nitrogen in surface microstructured silicon, prepared by fs-laser irradiation in gas mixture of SF₆/NF₃ and SF₆/N₂ were investigated. In both gas mixtures, nitrogen and sulfur were incorporated at average concentrations above 10¹⁹ atoms/cm³ in the 20–400 nm surface layer. Different crystallinity and optical absorption properties were observed for samples microstructured in the two gas mixtures. For samples prepared in SF₆/N₂, crystallinity and light absorption properties were similar to samples formed in SF₆. Significant differences were observed amongst samples formed in SF₆/NF₃, which possess higher crystallinity and strong sub-band gap absorption. The differing crystallinity and light absorption rates between the two types of nitrogen co-hyperdoped silicon were attributed to different nitrogen configurations in the doped layer. This was induced by fs-laser irradiating silicon in the two N-containing gas mixtures. Full article

(This article belongs to the Special Issue Ultrafast Laser-Based Manufacturing)

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6967 KiB

Open AccessArticle

Vibration-Assisted Femtosecond Laser Drilling with Controllable Taper Angles for AMOLED Fine Metal Mask Fabrication

by Wonsuk Choi, Hoon Young Kim, Jin Woo Jeon, Won Seok Chang and Sung-Hak Cho

Materials 2017, 10(2), 212; https://doi.org/10.3390/ma10020212 - 21 Feb 2017

Cited by 20 | Viewed by 7272

Abstract

This study investigates the effect of focal plane variation using vibration in a femtosecond laser hole drilling process on Invar alloy fabrication quality for the production of fine metal masks (FMMs). FMMs are used in the red, green, blue (RGB) evaporation process in Active Matrix Organic Light-Emitting Diode (AMOLED) manufacturing. The taper angle of the hole is adjusted by attaching the objective lens to a micro-vibrator and continuously changing the focal plane position. Eight laser pulses were used to examine how the hole characteristics vary with the first focal plane’s position, where the first pulse is focused at an initial position and the focal planes of subsequent pulses move downward. The results showed that the hole taper angle can be controlled by varying the amplitude of the continuously operating vibrator during femtosecond laser hole machining. The taper angles were changed between 31.8° and 43.9° by adjusting the vibrator amplitude at a frequency of 100 Hz. Femtosecond laser hole drilling with controllable taper angles is expected to be used in the precision micro-machining of various smart devices. Full article

(This article belongs to the Special Issue Ultrafast Laser-Based Manufacturing)

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2705 KiB

Open AccessArticle

Obtaining Cross-Sections of Paint Layers in Cultural Artifacts Using Femtosecond Pulsed Lasers

by Takaaki Harada, Stephanie Spence, Athanasios Margiolakis, Skylar Deckoff-Jones, Rebecca Ploeger, Aaron N. Shugar, James F. Hamm, Keshav M. Dani and Anya R. Dani

Materials 2017, 10(2), 107; https://doi.org/10.3390/ma10020107 - 26 Jan 2017

Cited by 10 | Viewed by 6810

Abstract

Recently, ultrafast lasers exhibiting high peak powers and extremely short pulse durations have created a new paradigm in materials processing. The precision and minimal thermal damage provided by ultrafast lasers in the machining of metals and dielectrics also suggests a novel application in obtaining precise cross-sections of fragile, combustible paint layers in artwork and cultural heritage property. Cross-sections of paint and other decorative layers on artwork provide critical information into its history and authenticity. However, the current methodology which uses a scalpel to obtain a cross-section can cause further damage, including crumbling, delamination, and paint compression. Here, we demonstrate the ability to make controlled cross-sections of paint layers with a femtosecond pulsed laser, with minimal damage to the surrounding artwork. The femtosecond laser cutting overcomes challenges such as fragile paint disintegrating under scalpel pressure, or oxidation by the continuous-wave (CW) laser. Variations in laser power and translational speed of the laser while cutting exhibit different benefits for cross-section sampling. The use of femtosecond lasers in studying artwork also presents new possibilities in analyzing, sampling, and cleaning of artwork with minimal destructive effects. Full article

(This article belongs to the Special Issue Ultrafast Laser-Based Manufacturing)

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10651 KiB

Open AccessArticle

Optically Clear and Resilient Free-Form µ-Optics 3D-Printed via Ultrafast Laser Lithography

by Linas Jonušauskas, Darius Gailevičius, Lina Mikoliūnaitė, Danas Sakalauskas, Simas Šakirzanovas, Saulius Juodkazis and Mangirdas Malinauskas

Materials 2017, 10(1), 12; https://doi.org/10.3390/ma10010012 - 02 Jan 2017

Cited by 113 | Viewed by 15190

Abstract

We introduce optically clear and resilient free-form micro-optical components of pure (non-photosensitized) organic-inorganic SZ2080 material made by femtosecond 3D laser lithography (3DLL). This is advantageous for rapid printing of 3D micro-/nano-optics, including their integration directly onto optical fibers. A systematic study of the fabrication peculiarities and quality of resultant structures is performed. Comparison of microlens resiliency to continuous wave (CW) and femtosecond pulsed exposure is determined. Experimental results prove that pure SZ2080 is ∼20 fold more resistant to high irradiance as compared with standard lithographic material (SU8) and can sustain up to 1.91 GW/cm² intensity. 3DLL is a promising manufacturing approach for high-intensity micro-optics for emerging ﬁelds in astro-photonics and atto-second pulse generation. Additionally, pyrolysis is employed to homogeneously shrink structures up to 40% by removing organic SZ2080 constituents. This opens a promising route towards downscaling photonic lattices and the creation of mechanically robust glass-ceramic microstructures. Full article

(This article belongs to the Special Issue Ultrafast Laser-Based Manufacturing)

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3396 KiB

Open AccessArticle

Effect of Repetition Rate on Femtosecond Laser-Induced Homogenous Microstructures

by Sanchari Biswas, Adya Karthikeyan and Anne-Marie Kietzig

Materials 2016, 9(12), 1023; https://doi.org/10.3390/ma9121023 - 19 Dec 2016

Cited by 32 | Viewed by 6679

Abstract

We report on the effect of repetition rate on the formation and surface texture of the laser induced homogenous microstructures. Different microstructures were micromachined on copper (Cu) and titanium (Ti) using femtosecond pulses at 1 and 10 kHz. We studied the effect of [...] Read more.

F_{Σ p u l s e}

) values and the effect on the surface texture through lacunarity analysis. Machining both metals at low

F_{Σ p u l s e}

resulted in microstructures with higher lacunarity at 10 kHz compared to 1 kHz. On increasing

F_{Σ p u l s e}

, the microstructures showed higher lacunarity at 1 kHz. The effect of the repetition rate on the threshold

F_{Σ p u l s e}

values were, however, considerably different on the two metals. With an increase in repetition rate, we observed a decrease in the threshold

F_{Σ p u l s e}

on Cu, while on Ti we observed an increase. These differences were successfully allied to the respective material characteristics and the resulting melt dynamics. While machining Ti at 10 kHz, the melt layer induced by one laser pulse persists until the next pulse arrives, acting as a dielectric for the subsequent pulse, thereby increasing

F_{Σ p u l s e}

. However, on Cu, the melt layer quickly resolidifies and no such dielectric like phase is observed. Our study contributes to the current knowledge on the effect of the repetition rate as an irradiation parameter. Full article

(This article belongs to the Special Issue Ultrafast Laser-Based Manufacturing)

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6070 KiB

Open AccessArticle

Numerical Approach to Modeling and Characterization of Refractive Index Changes for a Long-Period Fiber Grating Fabricated by Femtosecond Laser

by Akram Saad, Yonghyun Cho, Farid Ahmed and Martin Byung-Guk Jun

Materials 2016, 9(11), 941; https://doi.org/10.3390/ma9110941 - 21 Nov 2016

Cited by 3 | Viewed by 5811

Abstract

A 3D finite element model constructed to predict the intensity-dependent refractive index profile induced by femtosecond laser radiation is presented. A fiber core irradiated by a pulsed laser is modeled as a cylinder subject to predefined boundary conditions using COMSOL5.2 Multiphysics commercial package. The numerically obtained refractive index change is used to numerically design and experimentally fabricate long-period fiber grating (LPFG) in pure silica core single-mode fiber employing identical laser conditions. To reduce the high computational requirements, the beam envelope method approach is utilized in the aforementioned numerical models. The number of periods, grating length, and grating period considered in this work are numerically quantified. The numerically obtained spectral growth of the modeled LPFG seems to be consistent with the transmission of the experimentally fabricated LPFG single mode fiber. The sensing capabilities of the modeled LPFG are tested by varying the refractive index of the surrounding medium. The numerically obtained spectrum corresponding to the varied refractive index shows good agreement with the experimental findings. Full article

(This article belongs to the Special Issue Ultrafast Laser-Based Manufacturing)

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8953 KiB

Open AccessArticle

An Experimental Study on Micro Clinching of Metal Foils with Cutting by Laser Shock Forming

by Xiao Wang, Cong Li, Youjuan Ma, Zongbao Shen, Xianqing Sun, Chaofei Sha, Shuai Gao, Liyin Li and Huixia Liu

Materials 2016, 9(7), 571; https://doi.org/10.3390/ma9070571 - 13 Jul 2016

Cited by 16 | Viewed by 5812

Abstract

This paper describes a novel technique for joining similar and dissimilar metal foils, namely micro clinching with cutting by laser shock forming. A series of experiments were conducted to study the deformation behavior of single layer material, during which many important process parameters were determined. The process window of the 1060 pure aluminum foils and annealed copper foils produced by micro clinching with cutting was analyzed. Moreover, similar material combination (annealed copper foils) and dissimilar material combination (1060 pure aluminum foils and 304 stainless steel foils) were successfully achieved. The effect of laser energy on the interlock and minimum thickness of upper foils was investigated. In addition, the mechanical strength of different material combinations joined by micro clinching with cutting was measured in single lap shearing tests. According to the achieved results, this novel technique is more suitable for material combinations where the upper foil is thicker than lower foil. With the increase of laser energy, the interlock increased while the minimum thickness of upper foil decreased gradually. The shear strength of 1060 pure aluminum foils and 304 stainless steel foils combination was three times as large as that of 1060 pure aluminum foils and annealed copper foils combination. Full article

(This article belongs to the Special Issue Ultrafast Laser-Based Manufacturing)

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