Femtosecond Laser-Based Additive Manufacturing: Current Status and Perspectives

Metal Material Processing Using Femtosecond Lasers: Theories, Principles, and Applications

Metal material processing using femtosecond lasers is a useful technique, and it has been widely employed in many applications including laser microfabrication, laser surgery, and micromachining. The basic mechanisms of metal processing using femtosecond lasers are reviewed in this paper and the characteristics and theory of laser processing are considered. In addition to well-known processes, the recent progress relating to metals processing with femtosecond lasers, including metal material drilling, metal ablation thresholds, micro/nano-surface modification, printed circuit board (PCB) micromachining, and liquid metal (LM) processing using femtosecond lasers, is described in detail. Meanwhile, the application of femtosecond laser technology in different fields is also briefly discussed. This review concludes by highlighting the current challenges and presenting a forward-looking perspective on the future of the metal laser processing field.

Suppressing Metal Nanoparticle Ablation with Double-Pulse Femtosecond Laser Sintering

As a branch of laser powder bed fusion, selective laser sintering (SLS) with femtosecond (fs) lasers and metal nanoparticles (NPs) can achieve high precision and dense submicron features with reduced residual stress, due to the extremely short pulse duration. Successful sintering of metal NPs with fs laser is challenging due to the ablation caused by hot electron effects. In this study, a double-pulse sintering strategy with a pair of time-delayed fs-laser pulses is proposed for controlling the electron temperature while still maintaining a high enough lattice temperature. We demonstrate that when delay time is slightly longer than the electron-phonon coupling time of Cu NPs, the ablation area was drastically reduced and the power window for successful sintering was extended by about two times. Simultaneously, the heat-affected zone can be reduced by 66% (area). This new strategy can be adopted for all the SLS processes with fs laser and unlock the power of SLS with fs lasers for future applications.

Fabrication of Thin-Wall Structures with a Femtosecond Laser and Stainless Steel Powder

Additive Manufacturing (AM) has revolutionized the production of complex three-dimensional (3D) structures; however, the efficient and precise fabrication of thin profiles remains a challenge. This study explores the application of femtosecond-laser-based additive manufacturing techniques for the production of thin profiles with micron-scale features, reaching profile thicknesses below 100 µm. The study investigates the effects of scanning strategy, with optimized processing parameters, on the fabrication of thin profiles; wall thickness measurements were carried out using various technologies to analyse the influence of each on the resulting values. The quality of the walls was quantified by means of a visual characterization of the melted volumes, analysing the evolution of the measured thickness with regard to the processing conditions and in relation to the theoretical thicknesses of the walls.

An economical single-shot pulse picker without nonlinear effect and dispersion

An economical and stable single-shot pulse picker design without dispersion, nonlinear effect, and limitation on wavelength is proposed. This design is composed of a periodic pulse blocker (PPB), a control unit, and a mechanical shutter. It has successfully been applied to the commercial high-fluence femtosecond laser with 11-mm beam diameter, 2-mJ pulse energy, and 1-kHz repetition rate. Significantly, by incorporating commercial optical choppers equipped with custom-designed chopper blades in the PPB, this design can accommodate lasers with fluences reaching 610 mJ/cm2 and the standard 1 kHz repetition rate typical of high-fluence lasers. Furthermore, the proposed design provides a cost-effective substitute compared to using electro-optic modulators or acousto-optic modulators.

A Two-Step Femtosecond Laser-Based Deposition of Robust Corrosion-Resistant Molybdenum Oxide Coating

A two-step femtosecond-pulsed laser deposition (fs-PLD) process is reported for the rapid development of uniform, poreless, crack-free, and well-adhering amorphous coatings of source materials with a high melting point. The first step comprises a high-rate raw deposition of the source material via fs-PLD, followed by a second step of scanning the raw sample with fs laser pulses of optimized fluence and scan parameters. The technique is applied to develop substoichiometric molybdenum oxide (MoO_x, x < 3) coatings on mild steel. The thickness of the layer was ~4.25 μm with roughness around 0.27 μm. Comprehensive surface characterization reveals highly uniform and relatively moderate roughness coatings, implying the potential of these films as robust corrosion-resistant coats. Corrosion measurements in an aqueous NaCl environment revealed that the coated mild steel samples possess an average corrosion inhibition efficiency of around 95% relative to polished mild steel.

Potential hazards and mitigation of X-ray radiation generated by laser-induced plasma from research-grade laser systems

A large range of laser-matter applications employ ultrashort pulses and high laser intensity. Such processes can lead to unrequired X-ray generation, which represents a hazardous radiation factor even for common laboratory research-grade laser systems. We present here an analysis of the radiation dose rate and X-ray spectrum emitted during ablation of a rotating copper cylinder with respect to several laser parameters. The results show that focused sub-picosecond pulses with intensity above 10¹³ W/cm² can exceed the annual irradiation limit even in one hour, requiring appropriate shielding for the safety of the researchers.