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Related Experiment Video

Updated: Jan 19, 2026

Quantitative Analysis of Vacuum Induction Melting by Laser-induced Breakdown Spectroscopy
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Enhancement of laser material drilling using high-impulse multi-laser melt ejection.

Nan Shen, Jeff D Bude, Sonny Ly

    Optics Express
    |September 11, 2019
    PubMed
    Summary

    This study introduces a novel dual-laser technique combining continuous wave (CW) and pulsed lasers to significantly enhance material drilling rates and efficiency. The method achieves one to two orders of magnitude improvement for metals and composites.

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    Area of Science:

    • Materials Science and Engineering
    • Laser-Based Manufacturing
    • Additive and Subtractive Processes

    Background:

    • Current laser drilling and cutting technologies face limitations in throughput and efficiency.
    • Existing methods often struggle with achieving high aspect ratios and minimizing energy consumption.

    Purpose of the Study:

    • To develop and characterize a novel dual-laser approach for improved laser drilling.
    • To investigate the parametric dependencies of this new method on various materials and laser parameters.
    • To achieve significant increases in material removal rates and energy efficiency.

    Main Methods:

    • Utilized a gated continuous wave (CW) laser to generate a shallow melt pool.
    • Employed a UV picosecond (ps)-pulsed laser for impulsive melt expulsion.
    • Conducted a broad parametric study on common metals (Al, stainless steel) and carbon fiber composites, varying fluence, power, spot size, pulse length, sample thickness, and material properties.
    • Incorporated multi-laser material removal rate measurements, high-speed imaging of ejecta, and multi-physics hydrodynamic simulations.

    Main Results:

    • Demonstrated one to two orders of magnitude increase in average removal rate and efficiency compared to single-laser methods.
    • Achieved high aspect ratio holes (greater than 10:1) in samples up to 3 mm thick.
    • Exceeded published energy efficiency benchmarks for drilling these materials.
    • Observed similar enhancements in carbon fiber composites.

    Conclusions:

    • The dual-laser approach significantly enhances laser drilling performance for metals and composites.
    • High-impulse multi-laser interactions, driven by surface wave instabilities and melt cavitation/ejection, are key to the observed enhancements.
    • This method offers a more efficient and faster alternative for laser material processing applications.