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High power ultra short pulse laser processing - a new approach for high precision manufacturing Dr.-Ing. Arnold Gillner
Fraunhofer Institut für Lasertechnik, Aachen
James Watt Institute – Innovative Manufacturing Research Center Conference 2012 Laser Based Production Processes 26th June 2012
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From Milliseconds to Femtoseconds
Theodore Maiman (11.7.1927 – 5.5.2007)
Light Amplification by Stimulated Emission of Radiation
Ivan Ruddock demonstrates the first Femtosecond-Dye-Laser. Imperial College, London, 1970
Limited Application of Sophisticated and Expensive Research
?
(Gordon Gould, 1957)
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Ultra Short Pulse Lasers – A tool to overcome boundaries and explore new horizons
Valence band
Conduction band
Eph=DE 2Eph=DE
Absorption Temperature
Space Time
Ultra Short Pulse Lasers -
from fs to ps
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Thermal processing
)d3(
th
th
th
zierfc
AITzT 0,
Thermal penetration depth
Intensity
1
¼
time
2w Laserbeam
Isotherme
Solution of 1d- heat conduction problem:
4th
)d1(
th
c
Thermal conductivity [m2/s]
constant Pulse energy
Variation of Pulse length
High Intensity, short Pulse
heatimg of surface
low Intensity, long Pulse
diffusion into material
Temperature at end of
pulse 1
½
1 2 3
Materialdepth
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Ultra short pulse lasers
National Institute of Standards and Technology (NIST)
Regional Laser and Biomedical Technology Laboratories (RLBL) at the University of Pennsylvania
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Application fields for ultra short pulse laser processing
Mechanical Engineering Nano Manufacturing Electronics
Photovoltaics Life Science Metrology
• Tool Technology • Nozzle drilling • Turbine blade structuring • Glass processing
• Nano particle generation • Multi photon polymerisation • Functional surface processing • Laser chemistry
• Thin film processing • Organic electronics • Trimming • Mask repair
• Thin film processing • Precision drilling • Texturing • Materials modification
• Tissue ablation • Ophtalmologic applications • Bio fabrication • Intra cell processing
• Optical coherence tomography • Terahertz technology • Materials analysis • Bio diagnostics
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Laser Tooling with Ultra Short Pulsed Laser
Processing time10 Std.
Ablated volume 100 mm3
Surface quality similar to EDM-Processing Ra < 0.3 µm
No EDM-tools necessary
ns-Laser EDM ps-Laser
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Precision structuring of embossing tools
• Clear replication of CAD-Data • No melt and debris • Surface roughness < 0.5 µm
3D-Structuring of emboss ing rolls Material: Copper, chrome-plated Roll: 250 mm diameter, 1 m length Roller rotation speed: 1400 U/min Line scan distance : 2 µm -> surface speed: 15 m/s -> spot distance @ 2 MHz: 7,5 µm Laser power: 100 W Spot size: 10 µm Repetion rate: 3 MHz
5 mm
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Precision structuring of embossing tools
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Micro injection moulding of lens arrays in PMMA
Micro moulding tool for surface
structured parts
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20 µm
Structuring of injection moulding tool with Pikosecond lasers Lumera Rapid, = 355 nm Generation of multiple structures Structure size: 10 µm Sub structure: 2 µm Sub-Sub structure: 100 nm Replication by injection moulding Material: Polypropylen
Laser structuring for functional surfaces
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• Contact angle 174°
• Minimal Adhesion
• Rejection of capillary leads to removal of drop
• Drop is fixing on non structured surface
Laser structuring for functional surfaces
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Stainless-steel embossing tool
Surface structuring with ps laser
Structure size 800 nm
Roll embossing of polymer and Aluminium
Process speed 180 mm/min
Surface modification with nanostructured tools
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High speed structuring with ultra short pulsed lasers
ns-Ablation
• Melting of materials
• Post processing
necessary
• Processing speed
100 cm2/min
• Structure size > 50 µm
Non thermal ablation with
ultra short pulsed lasers
• Without post processing
• Structure accuracy < 2 µm
• Processing speed
500 cm2/min
• Structure size < 100 nm
• Combination Micro- and
Nano structure
Laser structuring for functional surfaces
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Laser structuring of motor components
Aim: Reduction of friction and wear
Approach: Micro and nano structuring of cylinder liners and piston rings
Use of high power ultra short pulsed lasers
Cylinder liner
Piston ring
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Strukturing of piston rings
Process ing parameter:
Lumera SuperRapid (1064nm, 10ps) on Deckel Maho Lasertec 40
spot size 20µm
Power: 0,2W
Scan speed : 120mm/s
Material: Chromium nitride (PVD) on steel (Stahl)
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High speed percussion micro drilling
Foil:
- 50 mm x 160 mm
- Thickness: 50 µm
Hole dimensions:
- = 13 – 16 µm
- Distance 50 µm
- 4 Mio Holes
- Processing with Scanner
- Scanfield 10 mm x 10 mm
- Drilling Speed:
1100 Löcher / s
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0
0.5
1.0 1.5
Superposition of 3 plane waves,
coplanar arragement
Three-Beam Interference Structuring:
zzxx ekekk
zzxx ekekk
zzekk
)cos(4)2cos(22),( 2 xkaaxkzxI xx
)cos(
)cos(
)cos(),,(
xkzkt
xkzkt
zktatzxE
xz
xz
z
Simulation: Three-Beam Interference in one Plane
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Linestructures in photoresist,
periodicity: 2.8µm
Intention:
Calculation of the sensitivity
of the intensity-modulation
depending on the alignment
of the sample in z-direction
optimal alignment
Three-Beam Interference Structuring:
misalignment about : 84µm
Simulation: Three-Beam Interference in one Plane
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Simulation of the intensity-distribution of the three coherent beams Polarization constellation: 0°,0°,0°
Software: Wolfram Mathematica 7
Three-Beam Interference Structuring:
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Simulation: Polarization: 0°,0°,0°
SEM-Image: Hole-structures in Pi*
*Polyimid Software: Matlab
Three-Beam Interference Structuring:
Simulation: Polarization: 0°,45°,90°
SEM-Image: Rectangular-structures in PI*
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(Detail) Diameter of the structure: 1µm Depth of the micro-holes: 600nm
Structures on Polyetheretherketone (PEEK):
Homogeneous structures over the entire spot. Diameter of the spot: 500µm
Three-Beam Interference Structuring:
5µm
„100,000 holes with one shot“
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Thin film structuring in solar cell production
P1: Ablation of Molybdenium-Layer P2: Ablation of CIGS-Absorber P3: Ablation of CIGS and TCO-Layer
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Thin film structuring in solar cell production
ns-Laser ablation of CIGS and TCO • Molydenium deterioration • CIGS-Melting
ps-Laser ablation of CIGS and TCO • No Molydenium deterioration • Low CIGS-Melting
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In-volume Selective Laser Etching, “ISLE”
fs laser radiation
v=1-100 mm/s
Wet etching
HF or KOH
Processing steps:
1) Selective modification of
the structure in the volume
by fs laser radiation
2) Selective etching of the
modified structure
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Examples for High Speed In-volume Micro Structuring
Tubes made of fused silica
Diameter and height: 1 mm
v=25 mm/s
P=250 mW
NA=0.3
Processing time: 60 s
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High Resolution Multiphoton Polymerisation
• Polymerisation initiated by absorption of two or more photons – requires high photon density
• Polymerized volume is restricted to the focus
• Direct 3D writing of micro-/nano Structures
• Large variety of materials:
• Elastic polymers
• Inelastic polymers
• Biomolecules/proteins
Sugio et al., 1999, Protein Engineering, 12, 6
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10 µm
BSA
Polymer
Polymer-Protein Hybrid Structures
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High power ultra short pulsed lasers and fast scanners
Development of high power
ultrafast lasers
• 10 ps-Laser with 20 MHz Rep-Rate
and P = 200 W
• 500 fs-Laser with 80 MHz Rep-Rate
and P = 300 W
Development of process adapted high speed
optical systems for ultrafast laser ablation
• High speed scanner systems
• Multiple beam optics for increase
of ablation rate
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Requirements on laser scanning for high repetition rate ultra fast lasers
Pulse overlap 10 – 50 %
Line overlap 10 %
Scanner specifications for typical micro ablation technology D = 20 µm Pulse overlap = 10 µm fLaser = 20 MHz Scanning speed = 200 m/s
Typical high precision Galvo-Scanner v < 10 m/s
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• Clear replication of CAD-Data
• No melt and debris
• Surface roughness < 0.5 µm
Material: Copper, chrome-plated
Roll: 250 mm diameter, 1 m length
Roller rotation speed: 1400 U/min
Line scan distance : 2 µm
-> surface speed: 15 m/s
-> spot distance @ 2 MHz: 7,5 µm
Laser power: 100 W
Spot size: 10 µm
Repetion rate: 3 MHz
5 mm
Structuring of embossing rolls
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High speed scanning technologies
Polygonial mirror
Single line scan
Scanning angles > 20°
Scanning speed > 100 m/s
Acustooptic deflectors
x-y-scanning
Scanning angles < 2°
Scanning speed > 100 m/s
Phased array deflectors
Single line scanning
Scanning angles > 20°
Scanning speed > 500 m/s
for EO-devices
Requirement from ultrafast laser machining @ f = 50 MHz and dspot = 20 µm
Scanning speed v = 500 – 1000 m/s
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High speed ablation with superimposed AOD and Galvo
AOD y-scan
Laser source
AOD x-scan
60% efficiency
Superposition of fast
scan with small scan
angle and slow scan with
large scan angle
Scan velocity up to
120m/s with arbitrary
scan figures
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High speed polygon scanning system
Laser system: Slab-Amplifier with Lumera Oscillator
Pulse duration: 12ps
Reprate: 10.7 MHz
Max. power: 230W (21.5µJ)
Polygon with 12 facets
Scan speed: max. 320 m/s
F-theta Linse f= 250 mm
Fokusdurchmesser: 60µm
Next step: Combination with Galvo Scanner
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Multi parallel processing with diffractive optical elements
mask
Laser source
DOE 2x2
1 2
3 4
suited for
periodic structures
split high
average laser
power into
numerous partial
beams
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High speed processing with ultra short pulsed lasers
Laser processes:
Drilling
Surface structuring
Applications:
Production of large filters with micro holes for water treatment
Production of microscaled vaporization masks for thin film deposition
Functional surface structuring
State of the art
Etching, mechanical drilling, lithography
Challenges :
High ablation rates
Large areas
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Ablation of 10-30 layers with ultra short pulsed lasers and high laser intensity
generation of structures with high structural aspect ratio (>10) and high absorbance of light (<95%)
Applications
Optical absorber
scattering area on transparent parts
Change of wetting behaviour
Surface enlargement
Functional Surfaces by selective Surface roughening
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Cutting and ablation of fiber reinforces polymers
Glass FRP tPulse = 10ps Rep.-rate: 100 kHz Pulsenergie: 30µJ VScan: 1m/s Ablation rate: 25µm
Carbon FRP tPulse = 500 fs Rep.-rate: 5.9 MHz Pulsenergie: 25 µJ VScan: 100 m/s Ablation rate: 120 mm³/s
Low impact processing of CFRP Cutting Trimming Drilling Partial ablation Surface preparation -> No delamination -> No thermal degradation
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Future Developments – High Precision at Large Components
Cutting of fiber reinforced polymers
Surface structuring
Large area processing
Low friction surfaces
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Dr. Arnold Gillner
Fraunhofer Institut für Lasertechnik Steinbachstraße 15 D-52074 Aachen
Tel: 0241 8906 -148 Fax: 0241 8906 -121 Email: [email protected] web.: www.ilt.fraunhofer.de
Thank you very much for attention
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Save the Date 2. Aachener Ultrakurzpuls-Workshop 17. – 18. April 2013