Open Access Article: Effects of Ultrashort Pulsed Direct Laser Writing on Ni/Al Reactive Multilayer Foils

Reactive multilayer foils for joining processes have attracted a great deal of attention over the last few decades. Previous studies have shown that ultrashort pulsed lasers can be used to structure these foils, allowing to tailor heat release characteristics without initiating a reaction. This publication investigates the microstructural changes that occur when femtosecond laser ablation is used on Ni/Al reactive foils. The effects of different laser parameters, such as pulse duration and repetition rate, on the heat affected zone were evaluated. The results demonstrate that femtosecond lasers are suitable for machining reactive foils with minimal heat input, and the heat affected zone was found to be negligible, extending to less than 100 nm. Furthermore, a new mechanism for debris redeposition trajectory was proposed, suggesting that the cutting process can be optimized to reduce debris redeposition or achieve a cleaner cut by adjusting the repetition rate and pulse energy.

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This work is part of DFG funded project “Tailored heat release characteristics for reactive joining processes”.