Micro pattern machined on a steel plate in less than 0.5 seconds

170 micron hole drilled on ceramic matrix composite

200 micron hole array

on  Ti-6Al-4V alloy

The goal of this project area is to develop various laser-based micro machining technologies. Research aims at providing a complete physical understanding of laser micro machining processes (applied to various materials) with different short and ultrashot lasers and the development of accurate predictive models that will enable optimization of the processes. Specific objectives of the research include:

• Micro hole drilling in the range of 10-1000 microns
• Laser-assisted micro milling of 3D structures
• Laser micro machining of 3D patterns using a pico-second laser
• Understand the underlying physics of laser-material interaction during ultrashort (ps and fs) laser ablation.
• Economic analysis of laser micromachining against current practice

The study of laser micromachining at Purdue is based on the simultaneous experimental and numerical investigations of the processes.  On the theoretical side, we aim at developing a better understanding of laser-material interaction and laser-plasma interaction.   Experimental work includes a systematic investigation of micromachining in terms of various parameters with measurement and monitoring of plasma development during laser ablation.   Two approaches under study include direct laser micromachining using ultrashort pulsed lasers (ps and fs) and laser-assisted micromachining.

Research Progress:

• Experimental facilities have been developed for laser micromachining with a pico-second laser and laser-assisted micromachining with micro endmills.
• Successful experimental studies have been conducted on micromachining of stainless steels, aluminum, titanium, silica, silicon nitride and SiC/SiC ceramic matrix composite.
• A predictive ablation model has been developed for ultrashort laser ablation.
• A thermal model has been developed for laser-assisted micro milling.
• Experimental studies on laser-assisted micromachining have been conducted on various materials including stainless steels, Inconel and Ti-6Al-4V alloys.

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Micromachined Part

Thermal Modeling for Laser-assisted Micromachining

Micro walls (15 mm thick and 90 mm tall) created by micromachining

Stent machined by an ultrashort laser

National Science Foundation
Indiana 21st Century Research and Technology
Industrial partners