Laser Material Research Articles

Ultrafast imaging of laser-induced modifications in planar targets via single-shot in-line holography

Abstract We present a holographic single-shot coherent diffractive imaging method based on in-line holography that allows the ultrafast characterization of 2D transmission maps of semi-transparent planar targets such as foils in amplitude and phase. Holographic information is obtained from the interference of the transmitted primary beam with the fields scattered from the modified or unknown target regions. A specialized iterative phase retrieval is used to incorporate the holographic nature of the approach and to accelerate and improve convergence. The achievable quality and reproducibility of the reconstructed transmission maps as well as optimal setup parameters are investigated using realistic pre-characterized reference targets. We used non-circular laser-induced hole structures in 30 nm thin gold foils that represent the final state of a laser modification and show that the far field error of the reconstructed diffraction images can be used to estimate and optimize the reconstruction quality in the object plane in order to obtain accurate and reproducible transmission maps. Our results mark the important first step towards the full spatio-temporal analysis of all stages of laser material modification or laser ablation in two-color pump probe experiments, including

Localized Laser Heat Treatment on AISI 1045 Steel Using a LPBF Laser

ABSTRACTLaser heat treatment (LHT) can provide local microstructure modification for metallic materials. This study investigates the viability of LHT on AISI 1045 steel using a laser designed for laser powder bed processing (LPBF) with a very small beam diameter compared to existing literature. Energy density models from the literature are analyzed and adapted to improve consistency across varying laser properties, mainly focusing on spot size and laser–material interaction time. Fifteen different laser parameter schematics are evaluated, comparing hardness versus depth relations as well as laser‐affected zone (LAZ) profiles. Through adapting the energy density model, new laser parameters are calculated and demonstrated to produce a valid localized heat treatment.

Probing rapid solidification pathways in refractory complex concentrated alloys via multimodal synchrotron X-ray imaging and melt pool-scale simulation

AbstractRefractory complex concentrated alloys (RCCAs) show potential as the next-generation structural materials due to their superior strength in extreme environments. However, RCCAs processed by metal additive manufacturing (AM) typically suffer from process-related challenges surrounding laser material interaction defects and microstructure control. Multimodal in situ techniques (synchrotron X-ray imaging and diffraction and infrared imaging) and melt pool-level simulations were employed to understand rapid solidification pathways in two representative RCCAs: (i) multi-phase BCC + HCP Ti0.4Zr0.4Nb0.1Ta0.1 and (ii) single-phase BCC Ti0.486V0.375Cr0.111Ta0.028. As expected, laser material interaction defects followed similar systematic trends in process parameter space for both alloys. Additionally, both alloys formed a single-phase (BCC) microstructure after rapid solidification processing. However, significant differences in microstructure selection between these alloys were discovered, where Ti0.4Zr0.4Nb0.1Ta0.1 showed a mixture of equiaxed and columnar grains, while Ti0.486V0.375Cr0.111Ta0.028 was dominated by columnar growth. These behaviors were well described by the influence of undercooling effects on columnar-to-equiaxed transition (CET). Distinct microstructure formation in each alloy was verified through CET predictions via analytical melt pool simulations, which showed a ~ 5 × increase degrees in undercooling for Ti0.4Zr0.4Nb0.1Ta0.1 compared to Ti0.486V0.375Cr0.111Ta0.028. Overall, these results show that microstructure control based on modulating the freezing range must be balanced with process considerations which resist defect formation, such as solidification crack formation in RCCAs. Graphical abstract

How laser material processing can benefit from OCT technology

AbstractUltrashort‐pulse (USP) laser ablation enables the creation of freeform shapes that are challenging to produce with conventional optics manufacturing techniques. To maintain the industrial standards of many branches, it is crucial to not only consider material removal rates but also the surface quality and subsurface damage (SSD). This study investigates the SSD patterns generated in fused silica and quantifies key parameters such as the SSD depth by applying optical coherence tomography (OCT).

Enhanced the quantum efficiency of Tm3+ ∼2 μm laser in crystal through an energy transfer process of 3H5 level

The concentration dependence of the fluorescence and lifetime evolutions of states relevant to three near-infrared emission bands were measured and analyzed for Tm:SrF2 crystals. The fast quenching of ∼1.2 μm fluorescence (3H5) was observed as the Tm concentration increased. The cross-relaxation and multi-phonon relaxation processes between Tm3+ ions cannot explain this phenomenon. Through spectral and rate-equation analysis, two possible energy transfer mechanisms, cross-relaxation from the 3H5 level and cooperative energy transfer within Tm3+ clusters, are proposed. And based on the new modified model, the quantum efficiency of the Tm ∼2 μm lasers could surpass the traditional 200% limit. This new energy transfer has the potential for exceptionally high efficiency excitation of Tm-doped laser materials.

How laser material processing can benefit from OCT technology

AbstractUltrashort‐pulse (USP) laser ablation enables the creation of freeform shapes that are challenging to produce with conventional optics manufacturing techniques. To maintain the industrial standards of many branches, it is crucial to not only consider material removal rates but also the surface quality and subsurface damage (SSD). This study investigates the SSD patterns generated in fused silica and quantifies key parameters such as the SSD depth by applying optical coherence tomography (OCT).

Investigations on opportunities and challenges of brilliant high-power laser beam welding with 24 kW and adjustable power distribution for different materials

Solid-state laser beam sources offer the possibility of generating high-brilliance laser beams with low expansion and high usable intensity at the focal point. New approaches include beam shaping with the use of core and ring fiber and, therefore, variable power distribution in the laser beam focal point and material interaction area. Particularly, high-power laser beam welding benefits from beam shaping because of the stabilizing effect on the weld pool. Furthermore, the technical progress achieved with regard to beam quality also allows one to achieve high Rayleigh lengths and, therefore, a more uniform beam diameter over the whole material thickness. In this study, investigations on high-power laser beam welding with a 24 kW disk laser beam source are conducted for three different materials (mild steel, aluminum alloy, and copper), which are of high interest for welding in different sectors. The influence of power distribution between the core and the ring as well as welding speed on weld geometry (depth and width), weld pool stability, and the resulting weld seam quality is investigated. It is shown that the welding process cannot just be scaled up in comparison with welding with lower laser beam power but has its own challenges. It is possible that high welding depths (12 mm for copper, more than 12 mm is possible for aluminum, and 25 mm for mild steel) could be achieved in one pass. To achieve this, aluminum needs the lowest energy per unit length per mm of sheet thickness and copper the highest.

Advances in Design and Fabrication of Micro-Structured Solid Targets for High-Power Laser-Matter Interaction

Accelerated particles have multiple applications in materials research, medicine, and the space industry. In contrast to classical particle accelerators, laser-driven acceleration at intensities greater than 1018 W/cm2, currently achieved at TW and PW laser facilities, allow for much larger electric field gradients at the laser focus point, several orders of magnitude higher than those found in conventional kilometer-sized accelerators. It has been demonstrated that target design becomes an important factor to consider in ultra-intense laser experiments. The energetic and spatial distribution of the accelerated particles strongly depends on the target configuration. Therefore, target engineering is one of the key approaches to optimizing energy transfer from the laser to the accelerated particles. This paper provides an overview of recent progress in 2D and 3D micro-structured solid targets, with an emphasis on fabrication procedures based on laser material processing. Recently, 3D laser lithography, which involves Two-Photon Absorption (TPA) effects in photopolymers, has been proposed as a technique for the high-resolution fabrication of 3D micro-structured targets. Additionally, laser surface nano-patterning followed by the replication of the patterns through molding, has been proposed and could become a cost-effective and reliable solution for intense laser experiments at high repetition rates. Recent works on numerical simulations have also been presented. Using particle-in-cell (PIC) simulation software, the importance of structured micro-target design in the energy absorption process of intense laser pulses—producing localized extreme temperatures and pressures—was demonstrated. Besides PIC simulations, the Finite-Difference Time-Domain (FDTD) numerical method offers the possibility to generate the specific data necessary for defining solid target material properties and designing their optical geometries with high accuracy. The prospects for the design and technological fabrication of 3D targets for ultra-intense laser facilities are also highlighted.

High quality factor, monodisperse micron-sized random lasers based on porous PLGA spheres.

Miniature random lasers with high quality factor are crucial for applications in barcoding, bioimaging, and on-chip technologies. However, achieving monodisperse and size-tunable biocompatible random lasers has been a significant challenge. In this study, we employed poly(lactic-co-glycolic) acid (PLGA), a biocompatible material approved for medical use, as the base material for random lasers. By integrating a dye-doped PLGA solution with a microfluidic system, we successfully fabricated monodisperse and miniature dye-doped PLGA spheres with tunable sizes ranging from 25 to 52 µm. Upon optical pulse excitation, these spheres exhibited strong random lasing emission at 610-640 nm with a threshold of approximately 22 µJ·mm-2. The lasing modes demonstrated a spectral linewidth of 0.2 nm, corresponding to a quality factor of 3100. Fourier transform analysis of the lasing emission revealed fundamental cavity lengths, providing insights into the properties of the random lasers.

Photodiode-based focus monitoring in ultrashort-pulsed laser structuring of graphite anodes for lithium-ion batteries

In recent years, there has been an increased demand for elaborate monitoring techniques in laser material processing. This has been driven by the need for fast and cost-efficient quality assurance processes. At the same time, ultrashort-pulsed (USP) laser radiation has emerged as a promising technology for creating intricate microstructures in lithium-ion battery graphite anodes due to its high precision and negligible thermal impact. However, the integration of process monitoring in USP laser applications for graphite anode structuring is still unexplored. There is a lack of clarity on suitable sensors, observable parameters, and extractable process-relevant insights. The presented study addressed this gap by demonstrating the capability of state-of-the-art photodiode-based monitoring systems in collecting process-relevant data and deriving valuable insights. A sensor equipped with three photodiodes was employed to address these challenges. Exploratory data analysis and machine learning methodologies were leveraged to develop a data pipeline for processing the acquired information. The data were used to train convolutional neural networks that could accurately predict the focal position. At the same time, the limitations of traditional regression approaches could be shown. The findings advanced the understanding of the possibilities of process monitoring in USP laser applications and emphasized the significance of data-driven approaches in optimizing manufacturing processes.

Process development and heat flow analysis for thin walls made of aluminum using extreme high-speed laser material deposition (EHLA3D)

Extreme high-speed laser material deposition (EHLA) is an adapted variant of directed energy deposition (DED-LB-P/M), also known as laser material deposition, and has been developed for the efficient manufacturing of thin layers with high deposition speeds. With precise control of the energy input into the powder gas jet and the substrate, EHLA allows deposition speeds of up to 200 m/min and weld beads as thin as 25 μm. Advantages include a smaller melt pool and a heat-affected zone, allowing the processing of difficult-to-weld material combinations. The development of EHLA for additive manufacturing (EHLA3D) aims to produce highly customized components with improved structural accuracy compared to standard LMD at increased build rates compared to laser powder bed fusion (PBF-LB/M). A promising application is complex lightweight structures for the aerospace industry. However, there is a lack of systematic investigation on lightweight materials processed with EHLA3D at feed rates >20 m/min. In this work, a specially designed tripod machine (maximum feed rate 200 m/min) was used to investigate the buildup of aluminum in process regimes at 30 m/min. After confirming the existing single-track parameters, the tracks were metallographically examined and checked for pores, cracks, and bonding defects. The process was applied to thin-wall geometries and line energies as well as return-times that were varied. To gain an understanding of process-induced heat development, the process was monitored using thermography. Since the process shows geometry-specific heat flow patterns, guidelines have been developed that enable the buildup using different process adaptions.

A New Organic Laser Material Design Toward Ultra-Low Amplified Spontaneous Red Emission and Ultra-Bright Electroluminescence.

Significant efforts are dedicated to developing new classes of organic semiconductor materials to achieve electrically pumped lasing. However, further advancements are necessary to understand the relationship between the structure and property for the creation of innovative laser materials with high stability, low triplet yield, ultra-low lasing threshold, and low-efficiency roll-off at ultra-bright electroluminescence. Here, a new design principle is validated for organic semiconductor laser materials, demonstrating simultaneous enhancement in the key figures of merit of low amplified spontaneous emission thresholds (Eth), efficient electroluminescence, and low triplet yields. By applying the Einstein stimulated emission rate equation and Strickler-Berg approximation, Two red-emitting laser dimers of Cibalackrot with different linkers are constructed, leading to giant enhancement (≈250%) in oscillator strengths, and stimulated emission cross-sections. When blended in poly(9,9-dioctylfluorene-alt-benzothiadiazole), the new dimers achieve an ultra-low Eth (4.5±0.3µJcm-2) in the deep red region (λASE=655nm), among the lowest reported for deep-red emitters. Organic light-emitting diodes (OLEDs) utilizing the dimer blend exhibit low-efficiency roll-off under DC mode. Under pulse operation, the OLEDs achieve high current densities (90Am-2) and ultrahigh brightness (≈710000cdm-2). These findings highlight the dimerization design as an excellent platform to advance organic semiconductor laser materials.

Photodiode-based process monitoring for the ultrashort-pulsed laser structuring of the diffusion media for fuel cells

In recent years, the incorporation of process monitoring systems has become an integral part across several laser material processing applications. This is due to the feasibility of inline evaluations, which enable the elimination of downstream quality checks that are typically time-consuming and costly. Simultaneous to recent sensor developments, ultrashort-pulsed (USP) laser material processing has become a promising technology for creating complex microstructures in a wide variety of materials due to its high precision and negligible thermal input. So far, process monitoring has yet to be established in USP applications as it is unknown which sensors are suitable, which parameters can be observed, and which process-relevant information can be detected within the data. Within this work, a state-of-the-art photodiode-based process monitoring system was used to collect spectral data from the process zone and extract relevant information from the process. The laser structuring of the two-layered diffusion media used in polymer electrolyte membrane fuel cells was selected as the use case. This structuring process is challenging due to production-related fluctuations in the material thickness and the surface quality. Within this study, information was acquired from a sensor system employing three photodiodes. Through the application of explorative data analysis techniques and machine learning, AI models were created, focusing on determining the focus position of the laser beam and identifying the transition between the two layers. The developed models were capable of determining the initial focus position with varying accuracies. The best performance was achieved by a convolutional neural network using spectrograms as input data, while the worst accuracy was achieved by a ridge regression model using manually selected features. Furthermore, a clustering model was used, demonstrating the capability to detect the layer transitions within a specified tolerance.

Enhanced 3 μm emission in Ho3+/Yb3+ co-doped bismuth-fluoride glasses by Gd2O3

In this work, (100-b)(45Bi2O3-40GeO2-15BaF2)-bGd2O3-2Yb2O3-0.5Ho2O3 glass was prepared to use a high-temperature melting method(where b= 0, 2.5, 5, 7.5, 10). The absorption and fluorescence spectra indicate that the optimal Gd2O3 content is 7.5 mol% (BGBG7.5HY), with an Ω2 value of 6.20×10−20 cm2 for the main glass, which is superior to that of BGBG0HY glass. This suggests that the incorporation of Gd2O3 enhances the mid-infrared emission capacity. Raman spectroscopy studies demonstrate that the introduction of Gd₂O₃ results in a substantial influx of oxygen atoms into the glass network, accompanied by a transition of [BiO₆] to [BiO₃] within the glass mesh. This is evidenced by a notable redshift of the characteristic peaks at 509 cm−1 and 677 cm−1 in comparison to BGB glass. The introduction of Gd2O3 also expands the distance between Ho3+/Yb3+ ions, inhibits rare earth ion clusters, improves the Ho3+ luminescence center environment, and thus enhances the 3 μm emission performance of bismuth fluoride glass. The maximum emission cross section is 1.82 × 10−20 cm2 and the maximum gain coefficient is 3.71 cm−1. The results show that the bismuth fluoride glass prepared in this paper is an excellent gain material for mid-infrared fiber lasers.

Review of high-precision femtosecond laser materials processing for fabricating microstructures: Effects of laser parameters on processing quality, ablation efficiency, and microhole shape

Femtosecond lasers are promising tools for achieving high-precision processing of thin materials without causing any thermal surface damage and bulk distortion. However, thermal damage can occur even with ultrashort laser pulses. This is because of high electron penetration depth and heat accumulation at high fluence and high repetition rate. Nanoparticle redeposition can be dramatically altered with variation in repetition rate. The symmetry of microholes and ablation efficiency vary with laser polarization. The laser wavelength affects the ablation efficiency and surface roughness. Therefore, understanding these laser–matter interactions that depend on the laser parameters is essential for high-precision laser processing. This article reviews laser–matter interactions in the 64FeNi alloy, as well as analytical models for designing the desired hole size and taper angles. This can help establish strategies for creating various high-precision microstructures using femtosecond lasers.

Yb:YSAG ceramics: An attractive thin-disk laser material alternative to a single crystal?

The 8.3 at.% Yb-doped yttrium-scandium-aluminum garnet (YSAG) ceramics were fabricated by a modified reverse co-precipitation method followed by uniaxial and cold isostatic pressing, annealing in air and high-temperature sintering in vacuum. Spectroscopic and lasing properties were investigated in dependence on Y/Sc/Al ratio in ceramic composition. Optical transmission of Yb:YSAG ceramics in visible and near-infrared spectral range exceeds 80 % that indicates a high quality of the Yb:YSAG samples. Among all the ceramics, the Y2.35Yb0.25Sc1.00Al4.40O12 composition demonstrates the best lasing performance and the highest slope efficiency up to 75 %.

Ultrastable and Low-Threshold Two-Photon-Pumped Amplified Spontaneous Emission from CsPbBr3/Ag Hybrid Microcavity.

Halide perovskite materials have garnered significant research attention due to their remarkable performance in both photoharvesting photovoltaics and photoemission applications. Recently, self-assembled CsPbBr3 superstructures (SSs) have been demonstrated to be promising lasing materials. In this study, we report the ultrastable two-photon-pumped amplified stimulated emission from a CsPbBr3 SS/Ag hybrid microcavity with a low threshold of 0.8 mJ/cm2 at room temperature. The experimental results combined with numerical simulations show that the CsPbBr3 SS exhibits a significant enhancement in the electromagnetic properties in the hybrid microcavity on Ag film, leading to the uniform spatial temperature distribution under the irradiation of a pulsed laser, which is conducive to facilitate the recrystallization process of the QDs and improve their structural integrity and optical properties. This study provides a new idea for the application of CsPbBr3/Ag hybrid microcavity in photonic devices, demonstrating its potential in efficient optical amplification and upconversion lasers.

Fundamentals of simultaneous machining and coating (SMaC) through combination of extreme high-speed laser material deposition (EHLA) and turning

Simultaneous machining and coating (SMaC) is a novel hybrid technology developed by the Fraunhofer Institute for Laser Technology ILT that combines additive manufacturing through extreme high-speed laser material deposition (EHLA) with a simultaneously engaged turning process. In the present work, the parallelization of the two subprocesses is successfully demonstrated. For the first time, systematic investigations into the influence of residual heat from the deposition process on the machining process and the properties of the resulting coating, respectively, are conducted. The study specifically examines geometric deviations, surface roughness, and tool wear. One of the main parameters affecting the residual heat introduced into the turning process is the distance between the tool center points of the EHLA deposition head and the turning tool Δz. This parameter is identified as a primary factor influencing the dimensional accuracy of the coating geometry. The results show that SMaC not only offers potential for increasing the productivity of the process chain but also has a positive effect on the service life of the cutting tools involved, potentially improving the workability of hard coating materials. Improvements in terms of the attainable surface roughness are also observed. These investigations provide a basis for research into further aspects of the SMaC process, such as adaptive tool path control methods to enhance dimensional accuracy and the influence of induced compressive stresses in processing highly brittle coating materials.

Growth and spectroscopic properties of Dy3+:GdCa4O(BO3)3 crystals

8 at.%, 10 at.%, and 12 at.% Dy3+ ions doped GdCa4O(BO3)3 crystals were successfully grown by the Czochralski method. The Raman spectrum showed that the maximum phonon energy was 937 cm−1. Detailed investigation of polarized absorption spectra, polarized fluorescence spectra, and fluorescence decay curve of the Dy3+:GCOB crystals showed that all the three crystals had good spectral properties. The strong and wide absorption peaks at 454 nm indicated that the crystals were fit for commercially available blue InGaN LD pumping. The intense and broad emission bands at around 585 nm, and long fluorescence lifetimes, revealed that the Dy3+:GCOB crystals were potential solid-state laser materials for yellow laser.

Thermal features and its effect on the properties of AISI 4140 fabricated by conventional and extreme high-speed laser material deposition

The extreme high-speed laser material deposition (EHLA) process has the potential to enable additive manufacturing for mass production by overcoming the limitations of slow scanning speed in conventional laser material deposition (LMD) processes. Thermal features are the key factors to link process and properties. A sound understanding of process-thermal-property relationships is essential for performance control and process optimization of a deposited component. In this study, we studied the thermal characteristics within a single layer and among layers for continuous processing using the numerical method, and reveal the mechanism of microstructure and hardness changes of AISI 4140 material formed by EHLA and LMD processes through the analysis of thermal properties and temperature history results. The grain size and hardness evolution for both processes during single-layer cladding and continuous forming processes were investigated. The results revealed that the grain refinement effect in continuous LMD processing is stronger than that in EHLA process (from 30.0 μm for single layer to 3.2 μm for multi layers vs. from 18.6 μm for single layer to 2.2 μm for multi layers). Similar hardness values were obtained by LMD and EHLA processes, with mean values of 511 HV and 472 HV, respectively. The yield and tensile strengths of EHLA were superior to the conventional cast material, but inferior to those of the conventional material quenched and tempered at lower temperatures. The enhanced tensile results of EHLA process were found similar to those prepared through conventional method with quench and tempering at 600 °C.