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Title: Enhancement of laser material drilling using high-impulse multi-laser melt ejection

Abstract

Laser drilling and cutting of materials is well-established commercially, although its throughput and efficiency limit applications. This work describes a novel approach to improve laser drilling rates and reduce laser system energy demands by using a gated continuous wave (CW) laser to create a shallow melt pool and a UV ps-pulsed laser to impulsively expel the melt efficiency and effectively. Here, we provide a broad parametric study of this approach applied to common metals, describing the role of fluence, power, spot size, pulse-length, sample thickness, and material properties. One to two order-of-magnitude increases in the average removal rate and efficiency over the CW laser or pulsed-laser alone are demonstrated for samples of Al and stainless steel for samples as thick as 3 mm and for holes with aspect-ratios greater than 10:1. Similar enhancements were also seen with carbon fiber composites. The efficiency of this approach exceeds published values for the drilling of these materials in terms of energy to remove a given volume of material. Multi-laser material removal rates, high-speed imaging of ejecta, and multi-physics hydrodynamic simulations of the melt ejection process are used to help clarify the physics of melt ejection leading to these enhancements. Our study suggests thatmore » these high impulse multi-laser enhancements are due to both laser-induced surface wave instabilities and cavitation of the melt for shallow holes and melt cavitation and ejection for deeper channels« less

Authors:
; ; ; ; ; ;
Publication Date:
Research Org.:
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
Sponsoring Org.:
USDOE National Nuclear Security Administration (NNSA)
OSTI Identifier:
1530647
Alternate Identifier(s):
OSTI ID: 1873227
Report Number(s):
LLNL-JRNL-779847
Journal ID: ISSN 1094-4087; OPEXFF
Grant/Contract Number:  
AC52-07NA27344
Resource Type:
Published Article
Journal Name:
Optics Express
Additional Journal Information:
Journal Name: Optics Express Journal Volume: 27 Journal Issue: 14; Journal ID: ISSN 1094-4087
Publisher:
Optical Society of America
Country of Publication:
United States
Language:
English
Subject:
70 PLASMA PHYSICS AND FUSION TECHNOLOGY; 42 ENGINEERING

Citation Formats

Shen, Nan, Bude, Jeff D., Ly, Sonny, Keller, Wesley J., Rubenchik, Alexander M., Negres, Raluca, and Guss, Gabe. Enhancement of laser material drilling using high-impulse multi-laser melt ejection. United States: N. p., 2019. Web. doi:10.1364/OE.27.019864.
Shen, Nan, Bude, Jeff D., Ly, Sonny, Keller, Wesley J., Rubenchik, Alexander M., Negres, Raluca, & Guss, Gabe. Enhancement of laser material drilling using high-impulse multi-laser melt ejection. United States. https://doi.org/10.1364/OE.27.019864
Shen, Nan, Bude, Jeff D., Ly, Sonny, Keller, Wesley J., Rubenchik, Alexander M., Negres, Raluca, and Guss, Gabe. Tue . "Enhancement of laser material drilling using high-impulse multi-laser melt ejection". United States. https://doi.org/10.1364/OE.27.019864.
@article{osti_1530647,
title = {Enhancement of laser material drilling using high-impulse multi-laser melt ejection},
author = {Shen, Nan and Bude, Jeff D. and Ly, Sonny and Keller, Wesley J. and Rubenchik, Alexander M. and Negres, Raluca and Guss, Gabe},
abstractNote = {Laser drilling and cutting of materials is well-established commercially, although its throughput and efficiency limit applications. This work describes a novel approach to improve laser drilling rates and reduce laser system energy demands by using a gated continuous wave (CW) laser to create a shallow melt pool and a UV ps-pulsed laser to impulsively expel the melt efficiency and effectively. Here, we provide a broad parametric study of this approach applied to common metals, describing the role of fluence, power, spot size, pulse-length, sample thickness, and material properties. One to two order-of-magnitude increases in the average removal rate and efficiency over the CW laser or pulsed-laser alone are demonstrated for samples of Al and stainless steel for samples as thick as 3 mm and for holes with aspect-ratios greater than 10:1. Similar enhancements were also seen with carbon fiber composites. The efficiency of this approach exceeds published values for the drilling of these materials in terms of energy to remove a given volume of material. Multi-laser material removal rates, high-speed imaging of ejecta, and multi-physics hydrodynamic simulations of the melt ejection process are used to help clarify the physics of melt ejection leading to these enhancements. Our study suggests that these high impulse multi-laser enhancements are due to both laser-induced surface wave instabilities and cavitation of the melt for shallow holes and melt cavitation and ejection for deeper channels},
doi = {10.1364/OE.27.019864},
journal = {Optics Express},
number = 14,
volume = 27,
place = {United States},
year = {2019},
month = {7}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record
https://doi.org/10.1364/OE.27.019864

Citation Metrics:
Cited by: 11 works
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