Ultrashort Laser Processing Research Articles

Surface structuring and in situ synthesis of nanoparticles by ultrashort laser processing on hydroxyapatite

Ultrashort laser pulses represent a versatile tool that finds application in a variety of fields allowing precise and controlled modification of any kind of materials. The material surface modification, by inducing the formation of micro and nanostructures or providing chemical changes, or its functionalization with other materials, in form of nanoparticles, strongly affects the behavior and performances of such materials. The surface structuring and the synthesis and deposition of metallic nanoparticles has both been obtained by laser exposure. The two processes are performed consecutively, on hydroxyapatite sample surface. The synthesis of silver nanoparticles (AgNPs) takes place on the sample surface, while immersed in a solution of silver nitrate (AgNO3), by laser-induced multiphoton photoreduction of silver ions (Ag+).

Review of Multi‑Scale Theoretical Research on Ultrashort Laser Processing and Coupling Model Construction (Invited)

Review of Multi‑Scale Theoretical Research on Ultrashort Laser Processing and Coupling Model Construction (Invited)

Ultra-short laser processing of 3D bioceramic, porous scaffolds designed by freeze foaming method for orthopedic applications.

Bone substitutes are widely employed for applications in orthopedic surgery for the replacement of injured bone. Among the diverse methods that are used to design 3D bioceramic matrices, Freeze Foaming has gained attention, since it provides the ability to tune the shape of the created structures. One of the major problems related to these constructs is the lack of porosity at the outwards sides (holder) of the scaffold, thus reducing the cellular affinity and creating a rejection of the implant. In this research, we aimed to develop a bone scaffold with enhanced surface properties and improved cellular affinity. The main aim was to alter the biocompatibility characteristics of the 3D bioceramic constructs. We have produced three-dimensional, complex-shaped hollow shell structures, manufactured by Additive Manufacturing processes and as a second step, filled with a ceramic suspension by the Freeze-Foaming process. 3D constructs from HAP-derived TCP and TCP/ZrO2 were synthesized by freeze-foaming method and subsequently irradiated with a fs-laser (λ = 800nm) spanning a range of parameters for achievement of optimal surface processing conditions. The designed scaffolds demonstrated enhanced topographical properties with improved porosity examined by SEM, EDX, and 3D profilometry after laser treatment. Wettability and computer tomography (CT) evaluation was also performed. The results from X-ray diffraction (XRD) and micro-Raman analysis did not show photochemical and surface or volume defects and changes after laser processing of the ceramic samples. Preliminary results from MG-63 osteoblast-like cell tests showed good cell affinity on the processed surfaces and no cytotoxic effect on the cells.

A Systematic Study on the Processing Strategy in Femtosecond Laser Scribing via a Two-Temperature Model.

Balancing quality and productivity, especially deciding on the optimal matching strategy for multiple process parameters, is challenging in ultrashort laser processing. In this paper, an economical and new processing strategy was studied based on the laser scribing case. To reveal the temperature evolution under the combination of multiple process parameters in the laser scribing process, a two-temperature model involving a moving laser source was developed. The results indicated that the peak thermal equilibrium temperature between the electron and lattice increased with the increase in the laser fluence, and the temperature evolution at the initial position, influenced by subsequent pulses, was strongly associated with the overlap ratio. The thermal ablation effect was strongly enhanced with the increase in laser fluence. The groove morphology was controllable by selecting the overlap ratio at the same laser fluence. The removal volume per joule (i.e., energy utilization efficiency) and the removal volume per second (i.e., ablation efficiency) were introduced to analyze the ablation characteristics influenced by multiple process parameters. The law derived from statistical analysis is as follows; at the same laser fluence with the same overlap ratio, the energy utilization efficiency is insensitive to changes in the repetition rate, and the ablation efficiency increases as the repetition rate increases. As a result, a decision-making strategy for balancing quality and productivity was created.

On the design and development of foamed GO-hydrogel nanocomposite surfaces by ultra-short laser processing

Graphene oxide (GO) and reduced graphene oxide have outstanding qualities that could be exploited as reinforcement and antibacterial agents in a plethora of biomedical applications. In this contribution, it is reported the deployment of a polyacrylamide GO-hydrogel composite (GO@pAAm) which was photo-converted and structured by ultra-short laser irradiation using a direct laser writing (DLW) approach. The materials were characterized by Fourier Transform Infrared spectroscopy, scanning electron microscopy and confocal microscopy. The laser structure generates a multi-photo-induced effect: surface foaming and patterning, microdomains with enhanced selective water-swelling and effective GO photo-reduction. A first laser scan seems likely to induce the photo-reduction of GO and subsequent laser pulses trigger the structure/foaming. The photo-reduction of GO is evidenced by Raman spectroscopy by the relatively changing intensities of the D to G signals. Macroscopically by an increase in conductivity (decrease in sheet resistance from R S-GO@pAAm = 304 ± 20 kΩ sq−1 to R S-rGO@pAAm-DLW = 27 ± 8 kΩ sq−1) suggesting a reduction of the material measured by 4-Point-Probe.

Creation of NV centers over a millimeter-sized region by intense single-shot ultrashort laser irradiation

Recently, ultrashort laser processing has attracted attention for creating nitrogen-vacancy (NV) centers because this method can create single NV centers in spatially-controlled positions, which is an advantage for quantum information devices. On the other hand, creating high-density NV centers in a wide region is also important for quantum sensing because the sensitivity is directly enhanced by increasing the number of NV centers. A recent study demonstrated the creation of high-density NV centers by irradiating femtosecond laser pulses, but the created region was limited to micrometer size, and this technique required many laser pulses to avoid graphitization of diamond. Here, we demonstrate the creation of NV centers in a wide region using only an intense single femtosecond laser pulse irradiation. We irradiated a diamond sample with a femtosecond laser with a focal spot size of 41 µm and a laser fluence of up to 54 J/cm2, which is much higher than the typical graphitization threshold in multi-pulse processing. We found that single-pulse irradiation created NV centers without post-annealing for a laser fluence higher than 1.8 J/cm2, and the region containing NV centers expanded with increasing laser fluence. The diameter of the area was larger than the focal spot size and reached over 100 µm at a fluence of 54 J/cm2. Furthermore, we demonstrated the NV centers’ creation in a millimeter-sized region by a single-shot defocused laser pulse over 1100 µm with a fluence of 33 J/cm2. The demonstrated technique will bring interest in the fundamentals and applications of fabricating ultrahigh-sensitivity quantum sensors.

MHz burst mode processing as a tool for achieving removal rates scalability in ultrashort laser micro-machining

The average power of ultrashort laser source has been increasing continuously and, therefore, solutions are required to employ fully these technology advances for improving the ablation efficiency in laser micro-processing. The use of burst mode processing is one of the solutions that has attracted a significant research and industrial interest in the past decade. A novel empirical methodology is proposed and implemented in this research to assess the MHz burst mode impact on the specific removal rate (SRR) and processing efficiency in ultrashort laser micro-machining. Especially, the capability of the MHz burst mode processing is investigated to scale up SRRs achievable on copper and stainless steel while utilising fully the available maximum pulse energy and average laser power. The results showed that the MHz burst mode offer a significant SRR scalability potential that can be attributed to beneficial near optimum fluence level and other side effects such as heat accumulation. Also, it is evidenced from the obtained results that the surface quality attained with the burst mode processing was comparable to that achieved with the single-pulse processing and even better at some specific process settings. Thus, the obtained SRR improvements were not in expense of the surface quality and the MHz bust mode processing represents a promising solution to employ fully the constantly increasing average power in ultrashort laser processing operations.

Optimization of titanium and titanium alloy surface properties by ultra-short laser processing for improved antibacterial characteristics

The aim of the current study is to improve in a one step process the properties of Ti and Ti alloy surfaces by enhancing their bioactivity in order to provide better conditions for microbial rejection. We propose to alter the biomaterial characteristics by a method alternative to the chemical ones, namely, non-contact processing of the surface by ultra-short laser pulses. The laser-induced modification results in a surface with different topographic features and an increased presence of oxides. We performed hierarchical laser patterning of the surface inducing the formation of areas covered by nanostructures, or laser-induced periodic surface structures (LIPSS), alternating with areas covered by micropillars in their turn surmounted by LIPSS. The increased roughness achieved due to the presence of micropillars, together with a marked presence of oxides, has been proven by several studies to enhance the biocompatibility of the material by improving the surface wettability and, furthermore, promoting the cells adhesion and osseointegration, while reducing the adhesion of pathogens.The laser processed surface, consisting of a pattern of parallel lines, showed improved and anisotropic wettability. The water contact angle value decreased by ∼10° in a direction orthogonal to the lines of the pattern, and by ∼40° in a parallel direction.

Molecular-dynamics study of multi-pulsed ultrafast laser interaction with copper

Ultrafast laser has an undeniable advantage in laser processing due to its extremely small pulse width and high peak energy. While the interaction of ultrafast laser and solid materials is an extremely non-equilibrium process in which the material undergoes phase transformation and even ablation in an extremely short time range. This is the coupling of the thermos elastic effect caused by the pressure wave and the superheated melting of the material lattice. To further explore the mechanism of the action of ultrafast laser and metal materials, the two-temperature model coupling with molecular dynamics method was used to simulate the interaction of the copper and laser energy. Firstly, the interaction of single-pulsed laser and copper film was reproduced, and the calculated two-temperature curve and the visualized atomic snapshots were used to investigate the influence of laser parameters on the ablation result. Then, by changing the size of the atomic system, the curve of ablation depth as a function of laser fluence was obtained. In this paper, the interaction of multi-pulsed laser and copper was calculated. Two-temperature curve and temperature contour of copper film after the irradiation of double-pulsed and multi-pulsed laser were obtained. And the factors which can make a difference to the incubation effect were analyzed. By calculating the ablation depth under the action of multi-pulsed laser, the influence of the incubation effect on ablation results was further explored. Finally, a more accurate numerical model of laser machining metal is established and verified by an ultra-short laser processing experiment, which provides a new calculation method and theoretical basis for ultra-fast laser machining of air film holes in aviation turbine blades, and has certain practical guiding significance for laser machining.

X-ray radiation protection aspects during ultrashort laser processing

Ultrashort pulse laser processing of materials allows for precise machining with high accuracy. By increasing the repetition rate to several 100 kHz, laser machining becomes quick and cost-effective. Ultrafast laser processing at high repetition rates and peak intensities above 1013 W/cm2 can cause a potential hazard by generation of unwanted x-ray radiation. Therefore, radiation protection must be considered. For 925 fs pulse duration at a center wavelength of 1030 nm, the x-ray emission in air at a repetition rate of 400 kHz was investigated up to a peak intensity of 2.6 × 1014 W/cm2. Based on the presented measurements, the properties of potential shielding materials will be discussed. By extending our previous works, a scaling of the x-ray radiation emission to higher peak intensities up to 1015 W/cm2 is described, and emitted x-ray doses are predicted.

X-ray radiation protection is necessary for ultrashort laser processing

Study reveals an X-ray hazard being present in industrial laser material processing with ultrashort laser pulses but can be overcome by using steel as shielding material.

Subwavelength Direct Laser Nanopatterning Via Microparticle Arrays for Functionalizing Metallic Surfaces

Functionalized metallic nanofeatures can be selectively fabricated via ultrashort laser processing; however, the cost-effective large-area texturing, intrinsically constrained by the diffraction limit of light, remains a challenging issue. A high-intensity near-field phenomenon that takes place when irradiating microsized spheres, referred to as photonic nanojet (PN), was investigated in the transitional state between geometrical optics and dipole regime to fabricate functionalized metallic subwavelength features. Finite element simulations were performed to predict the PN focal length and beam spot size, and nanofeature formation. A systematic approach was employed to functionalize metallic surface by varying the pulse energy, focal offset, and number of pulses to fabricate controlled array of nanoholes and to study the generation of triangular and rhombic laser-induced periodic surface structures (LIPSS). Finally, large-area texturing was investigated to minimize the dry laser cleaning (DLC) effect and improve homogeneity of PN-assisted texturing. Tailored dimensions and densities of achievable surface patterns could provide hexagonal light scattering and selective optical reflectance for a specific light wavelength. Surfaces exhibited controlled wetting properties with either hydrophilicity or hydrophobicity. No correlation was found between wetting and microbacterial colonization properties of textured metallic surfaces after 4 h incubation of Escherichia coli. However, an unexpected bacterial repellency was observed.

Ablation enhancement of metal in ultrashort double-pulse experiments

We report an ablation enhancement (both deepening and widening in ablation profiles) on nickel by ultrashort double-pulse laser irradiation, an exception of the typical reduction trend observed in ablation rates for metals irradiated with double-pulse excitations. Maximized at a pulse-separation (τs) of approximately 4 ps, the enhancement was observed before τs was increased to approximately the electron-lattice energy relaxation time. An achievement of ablation, by temporal shaping a weak pulse with energy well below the single-pulse ablation threshold into two considerably weaker pulses, was demonstrated. It is proposed that the enhanced electron-phonon coupling and drop of electronic heat conductivity, both of which result from the reductions in electron temperature (by pulse shaping), co-contribute to the widening in ablation profiles, while the former one is responsible for the deepening. This letter proposed an ablation enhancement approach to ultrashort laser processing of nickel.

Processing of ultra-hard materials with picosecond pulses: From research work to industrial applications

The ultrashort laser processing of the cutting tools and cutting inserts from tungsten carbide, ceramic and metal composites (CERMET), and polycrystalline diamond materials was demonstrated, and the ablation rates of mentioned ultra-hard materials were evaluated for a laser wavelength of 1064 and 532 nm. The optimal processing throughput was estimated. Laser manufacturing was performed with the five-axis computer numerical control (CNC) machine and scanner for beam translation with the high speed and the ultrashort ∼12 ps pulse duration high repetition rate laser source. The systematic approach was implemented in an experimental variation of process parameters that play a significant role in processing quality. By varying the laser fluence, pulse overlap, and layers’ count, different material removing rates can be achieved from 300 nm/layer to ∼18 μm/layer. The submicrometer removing rate involves a high precision control of the structure depth. It was demonstrated that only by a minor change of the processing parameters, the surface roughness of the material could be minimized down to Ra < 300 nm. Rough and smooth processing can be combined to optimize the structure processing throughput.

Spontaneous periodic ordering on the surface and in the bulk of dielectrics irradiated by ultrafast laser: a shared electromagnetic origin

Periodic self-organization of matter beyond the diffraction limit is a puzzling phenomenon, typical both for surface and bulk ultrashort laser processing. Here we compare the mechanisms of periodic nanostructure formation on the surface and in the bulk of fused silica. We show that volume nanogratings and surface nanoripples having subwavelength periodicity and oriented perpendicular to the laser polarization share the same electromagnetic origin. The nanostructure orientation is defined by the near-field local enhancement in the vicinity of the inhomogeneous scattering centers. The periodicity is attributed to the coherent superposition of the waves scattered at inhomogeneities. Numerical calculations also support the multipulse accumulation nature of nanogratings formation on the surface and inside fused silica. Laser surface processing by multiple laser pulses promotes the transition from the high spatial frequency perpendicularly oriented nanoripples to the low spatial frequency ripples, parallel or perpendicular to the laser polarization. The latter structures also share the electromagnetic origin, but are related to the incident field interference with the scattered far-field of rough non-metallic or transiently metallic surfaces. The characteristic ripple appearances are predicted by combined electromagnetic and thermo-mechanical approaches and supported by SEM images of the final surface morphology and by time-resolved pump-probe diffraction measurements.

Ultrafast laser processing of materials: from science to industry.

Processing of materials by ultrashort laser pulses has evolved significantly over the last decade and is starting to reveal its scientific, technological and industrial potential. In ultrafast laser manufacturing, optical energy of tightly focused femtosecond or picosecond laser pulses can be delivered to precisely defined positions in the bulk of materials via two-/multi-photon excitation on a timescale much faster than thermal energy exchange between photoexcited electrons and lattice ions. Control of photo-ionization and thermal processes with the highest precision, inducing local photomodification in sub-100-nm-sized regions has been achieved. State-of-the-art ultrashort laser processing techniques exploit high 0.1–1 μm spatial resolution and almost unrestricted three-dimensional structuring capability. Adjustable pulse duration, spatiotemporal chirp, phase front tilt and polarization allow control of photomodification via uniquely wide parameter space. Mature opto-electrical/mechanical technologies have enabled laser processing speeds approaching meters-per-second, leading to a fast lab-to-fab transfer. The key aspects and latest achievements are reviewed with an emphasis on the fundamental relation between spatial resolution and total fabrication throughput. Emerging biomedical applications implementing micrometer feature precision over centimeter-scale scaffolds and photonic wire bonding in telecommunications are highlighted.

Femtosecond laser structuring of novel electrodes for 3D fuel cell design with increased reaction surface

ABSTRACTThe scalable storage of renewable energy by means of converting water to hydrogen fuels electrochemically hinges on fundamental improvements in catalytic materials. However, many applications exist where an extended lifetime is virtually crucial for their functionality and success, e.g. in case of limited accessibility such as tire pressure sensors or biomedical implants. For these kinds of applications, the ultimate power supply should be a self-renewing energy source. This strategy is pursued by the concept of Micro Energy Harvesting (MEH). Within a MEH system a micro generator converts ambient energy to electrical energy for driving an application. Unfortunately, it is not ensured that the ambient energy level will maintain always high enough to provide sufficient power to the system as harvested energy usually manifests itself in rather irregular, random and low-energy bursts. One appealing form of integrated energy storage is the use of H2/air, a so called fuel cell type (FC) battery. Such devices promise very high volumetric energy densities of more than 2000 Wh/l. Consequently, this type of battery has recently attracted more and more attention and primary as well as secondary cells have been realized. Alkaline polymer electrolyte fuel cells have been recognized as the most promising solution in order to overcome the dependency on noble metal catalysts. Nevertheless, further improvements for these kinds of fuel cells have to be reached with respect to high power. Therefore, one promising approach is to increase the skin surface of porous chromium decorated nickel electrodes for enhancement of exchange current density by forming three-dimensional (3D) microstructures directly into the electrode. Therefore, a novel laser structuring process was applied using ultrashort laser pulses. Ultrashort laser processing of complex multimaterial systems for energy storage allow for precise material removal without changing the material properties. By applying this novel laser-based structuring technique, 3D microstructures could be formed permitting shortened diffusion lengths between the electrolyte and the electrode surface being necessary for increased exchange current densities.

Ultra-short laser processing of transparent material at the interface to liquid

Similarly to laser-induced backside wet etching (LIBWE) with nanosecond ultraviolet (ns UV) laser pulses, the irradiation of the solid/liquid interface of fused silica with sub-picosecond (sub-ps) UV and femtosecond near infrared (fs NIR) laser pulses results in etching of the fused silica surface and deposition of decomposition products from liquid. Furthermore, the etch threshold is reduced compared with both direct ablation with an fs laser in air and backside etching with UV ns pulses. Using 0.5 M pyrene/toluene as absorbing liquid, the thresholds were determined to be 70 mJ cm−2 (sub-ps UV) and 330 mJ cm−2 (fs NIR). Furthermore, an almost linear increase in the etch rate with increasing laser fluence was found. The roughness of surfaces backside etched with ultra-short pulses is higher in comparison with ns pulses but lower than that obtained using direct fs laser ablation. Hence a combination of processes involved in fs laser ablation and ns backside etching can be expected. The processes at the ultra-short pulse laser irradiated solid/liquid interface are discussed, considering the effects of ultra-fast heating, multi-photon absorption processes, as well as defect generation in the materials.

Improved Two-Temperature Model and Its Application in Ultrashort Laser Heating of Metal Films

The two-temperature model has been widely used to predict the electron and phonon temperature distributions in ultrashort laser processing of metals. However, estimations of some important thermal and optical properties in the existing two-temperature model are limited to low laser fluences in which the electron temperatures are much lower than the Fermi temperature. This paper extends the existing two-temperature model to high electron temperatures by using full-run quantum treatments to calculate the significantly varying properties, including the electron heat capacity, electron relaxation time, electron conductivity, reflectivity, and absorption coefficient. The proposed model predicts the damage thresholds more accurately than the existing model for gold films when compared with published experimental results.

Femtosecond laser ablation of polytetrafluoroethylene (Teflon) in ambient air

Teflon, polytetrafluorethylene (PTFE), is an important material in bioscience and medical application due to its special characteristics (bio-compatible, nonflammable, antiadhesive, and heat resistant). The advantages of ultrashort laser processing of Teflon include a minimal thermal penetration region and low processing temperatures, precision removal of material, and good-quality feature definition. In this paper, laser processing of PTFE in ambient air by a Ti:sapphire femtosecond laser (780 nm, 110 fs) is investigated. It is found that the pulse number on each irradiated surface area must be large enough for a clear edge definition and the ablated depth increases with the pulse number. The air ionization effect at high laser fluences not only degrades the ablated structures quality but also reduces the ablation efficiency. High quality microstructures are demonstrated with controlling laser fluence below a critical fluence to exclude the air ionization effect. The ablated microstructures show strong adhesion property to liquids and clear edges that are suitable for bio-implantation applications. Theoretical calculation is used to analyze the evolution of the ablated width and depth at various laser fluences.