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Study on Laser Drilling of Micro-Holes Using a Breakthrough Detection Method.

Liang Wang¹, Yefei Rong¹, Long Xu¹

¹Faculty of Mechanical and Materials Engineering, Huaiyin Institute of Technology, Huaian 223003, China.

Materials (Basel, Switzerland)

|August 28, 2025

Summary

This study introduces a new penetration detection method for precise laser drilling control. It optimizes pulse energy, defocus, and beam expansion for efficient, high-quality through-holes in stainless steel and titanium alloys.

Keywords:

304 stainless steel TC4 titanium alloy laser drilling millisecond laser penetration detection

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Area of Science:

Materials Science and Engineering
Manufacturing Processes
Laser Technology

Background:

Precise process control is crucial for efficient millisecond pulsed laser drilling of metallic through-holes.
Conventional methods for determining optimal laser drilling parameters have limitations.

Purpose of the Study:

To introduce a penetration detection-based method for determining the pulse count threshold in laser drilling.
To systematically investigate the effects of pulse energy, defocus, and beam expansion ratio on drilling quality and efficiency.
To establish a parameter database for high-quality laser drilling of 304 stainless steel and TC4 titanium alloy.

Main Methods:

Developed and applied a penetration detection-based method to identify the optimal pulse count threshold.
Conducted systematic experiments varying pulse energy, defocus, and beam expansion ratio.
Analyzed drilling quality (taper angle) and efficiency for 3 mm thick 304 stainless steel and TC4 titanium alloy.

Main Results:

For 304 stainless steel, minimum taper angle at 2.2 J pulse energy, -0.5 mm defocus, and 2.5 beam expansion ratio. High efficiency observed between 2.6-2.8 J pulse energy, -1 to 0 mm defocus, and 3-4 beam expansion ratio.
For TC4 titanium alloy, minimum taper angle at 2.6 J pulse energy, -0.5 mm defocus, and 3.5 beam expansion ratio. High efficiency recorded at 2.8 J pulse energy, -0.5 mm defocus, and 2.5-3 beam expansion ratio.
Stainless steel 304 exhibited higher drilling efficiency than TC4 titanium alloy under identical laser parameters.

Conclusions:

The penetration detection method provides a practical strategy for precise laser drilling control.
A valuable parameter database for efficient and high-quality laser drilling of stainless steel and titanium alloys has been established.
Optimized parameters differ between stainless steel 304 and TC4 titanium alloy, with stainless steel showing higher efficiency under similar conditions.