We report on high-quality high-throughput laser milling of silicon with a sub-ps laser delivering more than 1 kW of average laser power on the workpiece. In order to avoid heat accumulation effects, the processing strategy for high-quality laser milling was adapted to the available average power by using five-pulse bursts, a large beam diameter of 372 µm to limit the peak fluence per pulse to approximately
0.7
J
/
c
m
2
, and a high feed rate of 24 m/s. As a result, smooth surfaces with a low roughness of
S
a
≤
0.6
µ
m
were achieved up to the investigated milling depth of 313 µm while maintaining a high material removal rate of
230
m
m
3
/
min
.
Wavefront distortions caused by the convection of heated ambient air in front of the laser crystal induce severe pump-power-dependent misalignment in thin-disk laser (TDL) resonators. This effect is particularly pronounced in fundamental mode operation and limits the output power when no realignment of the resonator is possible during operation. In this Letter, we present a new approach to passively compensate for this misalignment instability by exploiting the spectral dispersion of a highly efficient grating-waveguide mirror used as a cavity end-mirror in a Littrow configuration. By this, it was possible to almost triple the output power of a fundamental mode Yb:LuAG TDL pumped at 969 nm.
The availability of commercial ultrafast lasers reaching into the kW power level offers promising potential for high-volume manufacturing applications. Exploiting the available average power is challenging due to process limits imposed by particle shielding, ambient atmosphere breakdown, and heat accumulation effects. We experimentally confirm the validity of a simple thermal model, which can be used for the estimation of a critical heat accumulation threshold for percussion drilling of AISI 304 steel. The limits are summarized in a processing map, which provides selection criteria for process parameters and suitable lasers. The results emphasize the need for process parallelization.
The development of high-power diode lasers enabled new solid-state laser concepts such as thin-disk, fiber, and Innoslab lasers based on trivalent ytterbium as the laser-active ion, which resulted in a tremendous increase in the efficiency and beam quality of cw lasers compared to previously used lamp-pumped rod or slab lasers and the realization of ultrafast lasers with several 100 W or even kilowatts of average power. In addition to their beneficial thermo-optical properties, these architectures offer characteristic benefits making them especially suitable to obtain dedicated laser properties. This review article comprises milestone developments, characteristic challenges, and benefits, and summarizes the state of the art of high-power solid-state lasers with the focus on ultrafast lasers.
We present an ultrafast laser with a near-diffraction-limited beam quality delivering more than 1.4 kW of average power in the visible spectral range. The laser is based on second harmonic generation in a lithium triborate crystal of a Yb:YAG thin-disk multipass amplifier emitting more than 2 kW of average power in the infrared.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.