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Drilling Sequence Optimization Using Evolutionary Algorithms to Reduce Heat Accumulation for Femtosecond Laser
Christian Lutz1, Jonas Helm1, Katrin Tschirpke1
1Applied Laser and Photonics Group, University of Applied Sciences Aschaffenburg, Würzburgerstraße 45, 63743 Aschaffenburg, Germany.
Materials (Basel, Switzerland)
|September 9, 2023
Summary
Optimizing laser drilling sequences with evolutionary algorithms significantly reduces workpiece heat accumulation. This allows for faster, high-quality borehole array production using multi-spot laser drilling.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Laser Physics
Background:
- Laser drilling of borehole arrays is crucial for various industrial applications.
- Heat accumulation during laser drilling can degrade workpiece quality and process efficiency.
- Current multi-spot laser drilling methods face challenges with managing thermal effects.
Purpose of the Study:
- To optimize laser drilling sequences for ultrashort pulsed lasers to minimize heat accumulation.
- To enhance the efficiency of borehole array fabrication using multi-spot laser drilling.
- To investigate the trade-offs between process speed, thermal management, and component quality.
Main Methods:
- Utilized evolutionary algorithms for optimizing drilling sequences.
- Employed spatial light modulators for multi-spot laser drilling.
- Verified results through thermal simulations (Comsol) and experimental thermal imaging.
- Investigated a 4x4 laser spot array for high-throughput drilling.
Main Results:
- Developed optimized drilling sequences that reduce temperature increase by approximately 35% compared to single-spot processes.
- Achieved high drilling efficiency, with a 4x4 array drilling 40,000 boreholes in under 76 seconds (526 boreholes/s).
- Demonstrated that optimized multi-spot sequences balance high efficiency with low thermal load and high component quality.
Conclusions:
- Optimized drilling sequences are essential for effective multi-spot laser drilling of borehole arrays.
- Evolutionary algorithms provide a robust method for achieving efficient and high-quality laser processing.
- This approach enables significant improvements in laser drilling throughput while maintaining component integrity.
