Advanced laser scanning for highly-efficient ablation and ultrafast surface structuring: experiment and model

Area of Science:

• Materials Science
• Laser Physics
• Surface Engineering

Background:

• Ultra-short laser pulses are crucial for material removal (ablation) across science, technology, and medicine.
• Inefficient laser energy utilization often results in low ablation rates, necessitating process optimization.
• Optimizing parameters like scanning speed, line distance, and spot size for rectangular cavities is time-consuming.

Purpose of the Study:

• To develop a theoretical understanding and a predictive model for efficient rectangular cavity laser ablation.
• To enhance laser energy utilization and increase material removal rates.
• To demonstrate high-speed fabrication of bio-inspired functional surfaces using laser irradiation.

Main Methods:

• A novel model for rectangular cavity ablation was developed, incorporating reduced ablation thresholds and ablation depth saturation.
• Experimental characterization of ablated depth and material removal rates using scanning electron microscopy and stylus profilometry.
• Numerical modeling was performed to validate the theoretical model against experimental data.

Main Results:

• The developed model accurately predicts material removal rates, showing good agreement with experimental results.
• The model accounts for key factors influencing ablation efficiency, such as pulse overlap and material properties.
• High-speed fabrication of complex, bio-inspired surfaces was successfully demonstrated.

Conclusions:

• The new ablation model provides a theoretical framework for optimizing laser parameters for efficient material removal.
• This approach significantly enhances laser energy efficiency and material removal rates in laser ablation processes.
• The validated model enables rapid, high-throughput manufacturing of functional surfaces, including bio-inspired designs.