Precise machining of disk shapes from thick metal substrates by femtosecond laser ablation

Abstract

Femtosecond-pulsed lasers have proven to be versatile for machining of microscale features in a variety of materials with minimal residual stress and heat-affected zone. However, machining of components from 200-μm-thick metal substrates by femtosecond laser ablation requires repetitive scanning of the laser beam focus along multiple adjacent paths numerous times to completely remove the part. In this study, optimization of multi-pass ablation parameters for efficient cutting and optimum final shape accuracy of disks of Stellite, aluminum, and stainless steel was investigated. The ablation depth of Stellite was measured with different pulse energies and groove widths, and 200 μm of diameter and thickness of Stellite disk were machined. The tapered cross-section of the disk was observed and increased pulse energy as the laser beam approached the bottom of the sample helped to minimize the taper angle of the sides of the disk. Moreover, the comparison of ablation depth in Stellite, aluminum, and stainless steel were conducted with various pulse energies and groove widths.

Systematic review of optimization techniques for laser beam machining

“…Laser beam ablation Sapphire [187], Copper [188], Steel [188], Silver [189], Diamond [190], Stellite [191], Aluminum [191], Stainless Steel [191], Alumina [192] Laser beam cutting Ceramics [30], Almg3 Aluminum Alloy [33], St37-2 Low-Carbon Steel [33], AISI 304 Stainless Steel [33], Stainless Steel 304 [42], Ti-6Al-4V Alloy [57,193], Coir Fibre/Carbon Fibre/ Epoxy Resin Hybrid Composite [108], Ti-Al Intermetallic Composite [194], Inconel-718 Alloy [80,100,141], Polycrystalline Diamonds [195], Polycrystalline Cubic Boron Nitrides And Tungsten Carbides [195], Cow Leather [74], Acrylonitrile Butadiene Styrene [196], Basalt Fiber Reinforced Composite [98], Bronze-Bonded Diamond [197], Kevlar-29/Basalt Fiber Reinforced Hybrid Composite [55], Kevlar-29 Composite [81], Nickel Based Superalloy [60],…”

Microfabrication of Sm2Co17 micromagnets for MEMS and micromotors using ultrashort pulsed hydro laser micromilling process

“…Ultrashort pulsed laser machining has been widely used in recent years to perform machining processes of micrometric structures and shapes in different materials like ceramics, metals and polymers [36]. Pulsed laser machining has been applied in several microfabrication processes: drilling [37], milling [38] grooving [39], and cutting free microparts [40] . Laser machining is also a promising method to cut and grind bulk magnets into small magnetic shapes without exerting mechanical forces.…”

Yb-Doped Fiber Chirped Pulse Amplification System Delivering 1 mJ, 231 fs at 1 kHz Repetition Rate

“…High energy femtosecond lasers are widely used in many industrial and academic fields [1][2][3]. In industry, femtosecond lasers have become mature instruments in material processing and surgical units.…”