SYSTEM AND METHOD LASER FOR PROCESSING OF MATERIALS
20200384572 ยท 2020-12-10
Inventors
- Pancho TZANKOV (Oxford, MA, US)
- Jonathan Ehrmann (Oxford, MA, US)
- Jeffrey Kmetec (Oxford, MA, US)
- Alexey Avdokhin (Oxford, MA, US)
- Andrei Babushkin (Oxford, MA, US)
Cpc classification
G02F1/3501
PHYSICS
G02B13/146
PHYSICS
G02F1/353
PHYSICS
G02F1/3503
PHYSICS
International classification
B23K26/06
PERFORMING OPERATIONS; TRANSPORTING
B23K26/067
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A multiple wavelength laser processing system is configured with a multiple wavelength laser source for generating a multiple wavelength coaxial laser processing beam. The laser processing system further includes a multiple wavelength optical system to deliver the coaxial laser processing beam to a laser-material interaction zone on the surface of a workpiece such that each of the a first and a second laser wavelengths in the processing beam impinge at least a portion of the interaction zone as respective first and second concentric laser spots. The multiple wavelength optical system includes a multiple wavelength beam collimator, a configurable chromatic optic, and a laser processing focus lens, wherein the configurable chromatic optic provides an adjustment to the relative focus distance of the first and second laser wavelengths.
Claims
1. A laser machining method of a workpiece comprising: partially converting a first broadband unpolarized fiber laser beam at a fundamental wavelength into at least one second beam at a harmonic wavelength; guiding the first beam and one second beam along a path with the first and second beams being coaxially and temporally overlapped; impinging the first and one second beams upon a surface of the workpiece having different absorption coefficients at respective fundamental and harmonic wavelengths; controlling a fluence ratio between the first and one second beams to be at least equal to the inverse absorption coefficients ratio at which the second beam provides a material state change and has a focal plane closer to the surface than a focal plane of the first beam so as to increase an absorption coefficient of the workpiece for the first beam.
2. The laser machining method of claim 1 further comprising generating an axial chromatic aberration between the first and second beams such that the first beam has a focus within the workpiece at a distance from the surface, and the second beam has a second focus spaced upstream from the first focus.
3. The laser machining method of claim 2, wherein controlling the fluence ratio includes: displacing non-achromatic optics, which generates the achromatic aberration along the path, or replacing the non-achromatic optics with another, which is configured with different refractive curvatures or made from different optical material such as Fused Silica, CaF.sub.2, or MgF.sub.2, or others capable of altering respective focal distances of the first and second beams.
4. The laser machining method of claim 2, wherein inverted ratio I a ratio of absorption coefficients at respective fundamental and harmonic wavelength.
5. The laser machining method of claim 1 or 2 further comprising controlling a harmonic conversion efficiency of the first beam into the second beam, thereby adjusting the fluence ratio on the workpiece surface to be higher than the inverse absorption coefficients ratio, wherein the machining method is achieved with less total laser power at all wavelength than would be required in the absence of the second beam.
6. The laser machining method of claim 1, wherein the harmonic wavelength of the second beam includes second, third and/or fourth harmonic wavelength or at an independently tunable wavelength by using optical parametric and/or Raman processes. Note that all or multiple beams at those wavelength may be impinging at the workpiece surface at the same time and position.
7. The laser machining method of claim 1 further comprising creating a plasma to increase the absorption coefficient of the workpiece for the first beam.
8. The laser machining method of claim 1 further comprising collimating achromatically the first and the second coaxial beams after the generation of the second beam by using one or more mirrors only.
9. A laser machining method of a workpiece comprising: converting a part of a first broadband unpolarized fiber laser beam at fundamental wavelength into at least one second broadband beam at a harmonic wavelength, wherein an unconverted portion of the first beam and the second beam are coaxially and temporally overlapped; guiding the first and second beams along a path through a non-achromatic optics, thereby generating chromatic aberration between the beams such that when the beams simultaneously impinge upon a surface of the workpiece, made from a material with different absorption coefficients at respective fundamental and harmonic wavelength, the second beam with a focus at the surface provides a material state change increasing the absorption coefficient in the workpiece for the first beam with a focus thereof spaced from the surface into or out of the workpiece.
10. The method of claim 9 further comprising adjusting a fluence ratio of the first and second beams at respective fundamental and harmonic wavelength to provide the material state change, the fluence ratio being at least equal to an inverted ratio of a absorption coefficients at the fundamental and harmonic wavelength.
11. The method of claim 9 further comprising controlling a harmonic conversion efficiency of the first beam into the second beam, wherein the material state change is provided if the conversion efficiency is larger than the inverse absorption ratio at each of the fundamental and harmonic wavelength.
12. The laser machining method of claim 11, wherein the wavelength conversion efficiency is controlled to prevent degradation of a Gaussian intensity distribution of the first beam, which is single or multi-mode beam, to a donut-shaped intensity distribution during the conversion.
13. The laser machining method of claim 11, wherein the wavelength conversion efficiency is controlled to provide a donut-shaped intensity distribution profile of the first beam.
14. The laser machining method of claim 11, wherein the material state change is provided if the energy of each of the first and second beams incident on the workpiece is
Eth()/Ethall()>1, wherein Eth() is the energy threshold of the laser beam coupled into the workpiece at each individual fundamental or harmonic wavelength alone needed to accomplish the laser machining of workpiece by a single beam, and Ethall() is the energy threshold of the laser beam at the individual wavelength when the coaxial first and second beams impinge on the workpiece simultaneously.
15. The laser machining method of claim 9, wherein the second beam has the harmonic wavelength selected from second, third and fourth harmonic and a combination of these wavelength of the fundamental wavelength and/or independently tunable wavelength generated by optical parametric or Raman processes.
16. The laser machining method of claim 9 further comprising generating an electron plasma by the second beam upon impinging the surface of the workpiece which is made from a material having an absorption coefficient at the second beam wavelength higher than the absorption coefficient at the fundamental wavelength.
17. The laser machining method of claim 9 further comprising heating the surface of the workpiece made by the fundamental wavelength that increases significantly the absorption at the higher wavelength.
18. The laser machining method of claim 9, wherein the beam at the fundamental wavelength includes a plurality of single and/or multi-mode laser light emitted at 0.9-2.1 m wavelength range and having a pulse duration in a seconds-femtosecond range, an M.sup.2 factor between 1 and 100, a broad spectral line between 2 nm and hundreds of nm, a pulse energy in a JJ range, and an average power between single-digit watt and few hundreds of kilowatts; the second beam spectral line width exceeding 0.5 nm.
19. The laser machining method of claim 9 further comprising collimating achromatically the first and the second coaxial beams after the generation of the second beam by using one or more mirrors only.
20. The laser machining method of claim 9, wherein the first beam is single mode or multimode beam generated by a fiber laser operating in a pulsed, continuous wave (CW) or quasi CW (QCW) mode.
21. A modular laser machining apparatus of a workpiece comprising: a tunable harmonic generator operative to partially convert a first broadband unpolarized fiber laser beam at a fundamental wavelength into at least one second broadband beam at a harmonic wavelength, the first and second beams being coaxial and temporally overlapped and simultaneously impinging upon a surface of the workpiece which has different absorption coefficients at respective fundamental and harmonic wavelength; a system operative to adjust a fluence ratio between the first and second beams to be at least equal to a threshold value at which the second beam provides a material state change on or near the surface so as to increase an absorption coefficient of the first beam.
22. The laser machining apparatus of claim 21 further comprising non-achromatic optics located between the tunable harmonic generator and the workpiece and operative to generate an axial chromatic aberration between the unconverted first and second beams such that the first beam has a focus within the workpiece at a distance from the surface, and the second beam has a second focus spaced upstream from the first focus closer to the surface.
23. The laser machining apparatus of claim 22, wherein the controller is configured with a fluence measuring unit operative to measure the fluence, a processing unit operative to determine the fluence ratio and compare the measure to the threshold value and an actuator operative to displace the non-achromatic optics or replace the non-achromatic optics or displace and replace the non-achromatic optics.
24. The laser machining apparatus of claim 21, wherein the threshold value is at least equal to an inverted ratio of a absorption at the fundamental and harmonic wavelength.
25. The laser machining apparatus of claim 24 further comprising a system for controlling a harmonic conversion efficiency of the first beam into the second beam to be larger than the inverse absorption coefficients ratio at each of the fundamental and harmonic wavelength.
26. The laser machining apparatus of claim 1, wherein the tunable harmonic generator is operative to convert the first beam into second beam at second, third and fourth harmonic wavelength.
27. The laser machining method of claim 21 further comprising collimating achromatically the first and the second coaxial beams after the generation of the second beam by using one or more mirrors only.
28. A modular system for machining a workpiece, comprising: a laser source outputting a broadband first beam at a fundamental wavelength along a path; a harmonic wavelength generator receiving the first beam and operative to partially convert the first beam into at least one second beam at a harmonic wavelength, wherein the first and the second beams are coaxially and temporally overlapped; and an adjustable non-achromatic optics impinged upon by the coaxial first and second beams and configured to controllably generate a chromatic aberration such that the second beam has a focal plane on or near a surface of the workpiece providing an initial material state change sufficient to increase a temperature for a subsequent effective absorption of the first beam with a focal plane spaced away from the surface into a body of the workpiece.
29. The modular system of claim 28, wherein the laser source is a fiber laser operating in a continuous wave (CW) mode or quasi-CW mode or pulsed mode and outputs the first beam in single or multi modes.
30. The modular system of claim 28, wherein the harmonic generator is configured with: one or more nonlinear crystals spaced from one another along the optical path by using only reflective focusing so as to selectively provide sequential conversion of the fundamental wavelength into second, third and/or fourth harmonic wavelength, or at an independently tunable wavelength by using optical parametric and/or Raman processes and a single or multi-pass wavelength conversion scheme.
31. The modular system of claim 30, wherein the nonlinear crystals each are cut for either Type I or Type II phase-matching.
32. The modular system of claim 28 further comprising a collimator including a parabolic mirror which is located between the harmonic generator and the workpiece.
33. The modular system of claim 28 further comprising a processing unit configured to determine a fluence ratio of the first and second beams at respective fundamental and harmonic wavelength and adjust the non-achromatic processing lens or lens system such that the second beam at the higher wavelength generating the spark, wherein the fluence ratio is larger or at least equal to an inverted ratio of a absorption coefficients at the fundamental and harmonic wavelength.
34. The modular system of claim 33, wherein the processing unit is operative to adjust a wavelength conversion efficiency of the harmonic generator to be larger than the inverted absorption coefficient ratio at each of the fundamental and harmonic wavelength.
35. The modular system of claim 34, wherein the processing unit is operative to control the wavelength conversion efficiency to prevent degradation of a Gaussian intensity distribution of the first beam to a donut-shaped intensity distribution during the wavelength conversion.
36. The laser machining method of claim 34, wherein the wavelength conversion efficiency is controlled to provide a donut-shaped intensity distribution profile of the first beam which can be a single mode or multi-mode beam.
37. The laser machining method of claim 28, wherein the fiber laser source operates so that the energy of each of the first and second beams incident on the workpiece is
Eth()/Ethall()>1, wherein Eth is the energy threshold of a single laser beam coupled into the workpiece at each individual fundamental or harmonic wavelength alone needed to accomplish the laser machining of workpiece by the single laser beam at the individual wavelength beam, and Ethall() is the energy threshold of the laser beam at the individual wavelength when the coaxial first and second beams impinge on the workpiece simultaneously all together.
38. A method for laser machining comprising: determining a desired harmonic fluence level at a target surface to effect a state change in the surface material, wherein the desired fluence level will at least initiate a laser machining process, setting a harmonic spot size, a conversion efficiency, and an unconverted beam power to achieve the desired harmonic fluence level, determining a fundamental spot size corresponding to the desired harmonic fluence and harmonic spot size, the fundamental beam comprising residual unconverted radiation, configuring a chromatic optical system to coaxially deliver the harmonic spot size and the fundamental spot size to the target surface, and Delivering laser radiation to the target work surface with the chromatic optical system to efficiently process target material.
39. A multiple wavelength laser processing system comprising: a multiple wavelength laser source for generating a multiple wavelength coaxial laser processing beam, a multiple wavelength optical system to deliver the coaxial laser processing beam to a laser-material interaction zone on the surface of a workpiece such that each of the a first and a second laser wavelengths in the processing beam impinge at least a portion of the interaction zone as respective first and second concentric laser spots, the multiple wavelength optical system comprising a multiple wavelength beam collimator, a configurable chromatic optic, and a laser processing focus lens, wherein the configurable chromatic optic provides an adjustment to the relative focus distance of the first and second laser wavelengths.
40. The system as in claim 39, wherein the diameter ratio of the first and second laser spots is adjusted by configuring the chromatic optic.
41. The system as in claim 39, wherein the diameter of the smaller concentric spot is less than % the diameter of the larger concentric spot.
42. The system as in claim 39, wherein the configurable chromatic optic is removable from the path of the coaxial beam, the system having a first set of respective focus distances with the chromatic optic installed, and a second set of respective focal distances when the chromatic optic is removed.
43. The system as in claim 39, wherein the configurable chromatic optic comprises a first chromatic optic that is interchangeable with a second chromatic optic, the system having a first set of respective focus distances corresponding to the first chromatic optic, and a second set of respective focal distances corresponding to the second chromatic optic.
44. The system as in claim 39, wherein the configurable chromatic optic comprises a first removable chromatic optic and a second removable chromatic optic, the system having a plurality of sets of respective focus distances corresponding a plurality chromatic optic configurations.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The above and other features and advantages of the present disclosure will become more readily apparent from the specific description and claims accompanied by the following drawings, in which:
[0025]
[0026]
[0027]
[0028]
[0029]
[0030]
[0031]
[0032]
[0033]
SPECIFIC DESCRIPTION
[0034] The basic concept of this disclosure includes laser treating a workpiece with two or more laser beams at different wavelengths which are differently absorbed by the material to be treated at room temperature. The energy of one of the beams at the wavelength, which is absorbed more effectively than that of the other beam at room temperature, is coupled into the material inducing a material state change. With the material change occurred, the workpiece effectively absorbs the other beam or beams at respective wavelengths. Optimization of the disclosed process allows the disclosed method and system successfully treat practically any material. For example, it can be glass, sapphire, ceramics, copper, corroded metals, thin metals, biotissues, PCBs and silicon wafers.
[0035]
[0036] The generation of other beams at respective wavelengths different from that of beam 18 is realized by a harmonic frequency generator 14. The latter may operate on a basis of different physical mechanisms, but ultimately regardless of the configuration, generator 14 is operative to partially convert the wavelength of beam 18 to a different wavelength of beam 20 with a spectral line width exceeding 0.5 nm. Within the scope of the disclosure, frequency harmonic generator 14 may be operative to use a variety of conversion processes including frequency doubling, sum and difference frequency generation in nonlinear crystals, parametric oscillation and amplification in nonlinear crystal materials, and Raman conversion in bulk crystals or in optical fibers. Examples of specific optical schematics are discussed in detail below.
[0037] Propagating along the light path in a coaxial manner, beams 18 and 20 impinge on a chromatic adjuster 16 configured with one or multiple lenses as explained below. The chromatic adjuster 16 generates an axial chromatic aberration between the first and second beams which further impinge simultaneously a workpiece made from material 22. When using chromatic adjuster 16, beam 18 at the longer wavelength will have a focus farther from that of beam 20 at the shorter wavelength which is on or near the surface of material 22. As a consequence, at the focal point of beam 20, beam 18 forms a spot diameter larger than that of beam 20. Hence the intensity of beam 18 at the longer wavelength at the focal point of beam 20 is significantly lower than at its own focal point. Because of the difference in spot diameters, the fluence ratio between beams 20 and 18 is usually 2-10 times higher, depending on the material of chromatic system 16, than in case of achromatic lens systems of the prior art, wherein the fluence is the pulse energy per beam areas in case of QCW and pulsed lasers, and power per beam area for CW lasers.
[0038] The fluence ratio is important for disclosed system 10 that is configured to control a minimal amount of beam 20 needed to provide the desired material state change leading to the increased absorption of beam 18 and thus to more efficient use of the entire system. Note that utilizing high power laser source 12, typically beam 18, such as an IR beam, can laser treat many materials, but the use of only one IR beam 18 would lead to unacceptably inefficient process. The same relates to any other single wavelength light that in principle may individually treat material 22, but may render the laser treatment process inefficient. The use of multiple beams instead of processing the same material with one beam can be analytically expressed as
Eth()/Ethall()>1,
wherein Eth() is the energy threshold of each individual beam which is needed to process the workpiece alone without the assistance of other wavelengths, and Ethall() is the energy threshold of the same laser beam in the multi-beam of the disclosure, i.e. when all wavelengths are present simultaneously. When the above is met the efficiency of the process utilizing the disclosed system can be enhanced by orders of magnitude in some applications. Typical pulse energies in the applications with multiple beams are 4-5 times the single pulse threshold energies Eth.
[0039] The fluence ratio between beams 20 and 18 in system 10 is obtained on the basis of well documented dependence of absorption according to wavelength for various materials at ambient temperature, as shown in
[0040] The fluence ratio can be adjusted by several techniques. On the techniques includes manipulating the chromatic aberration of chromatic adjuster 16 by replacing currently installed lens set with a different one which may be made from different materials, such as Fused Silica (FS), magnesium fluoride (MGF2), calcium fluoride (CAF2) and others. Still another technique provides for adjusting the conversion efficiency. The selection of chromatic adjuster 16 appropriate for the task at hand can be realized by any mechanical method including an automated lens delivering mechanism. The techniques for adjusting parameters of the wavelength conversion are also well known to one of ordinary skill in the laser arts and may include controllably varying the geometry and temperature of NL crystals or the length of Raman fiber and many others. While the conversion is controllably adjusted, the power profile of pulses, as shown in
[0041] Typically the laser used in laser material processing are configured narrow band and polarized to provide good harmonic conversion efficiencies. However, the high conversion efficiency comes with significant degradation of the fundamental beam profile, as shown in
[0042]
[0043]
[0044] With broadband laser source 12 and with multiple laser wavelengths, a monochromatic processing lens design will generally exhibit so-called chromatic aberrations. These aberrations are a result of material dispersion, variations in the index of refraction with wavelength. With different indices of refraction, the focal length of the lens depends on the wavelength, and results in axial chromatic aberration where different wavelengths focus at different focal distances.
[0045] The chromatic adjuster may have a variety of configurations. For example, an air-spaced chromatic doublet of suitable optical materials may be used as a chromatic corrector to adjust the beam collimation of one wavelength relative to another as input to the processing lens to correct axial chromatic aberrations of a processing lens or to intentionally add chromatic aberration for focal distance separation at multiple wavelengths.
[0046] The chromatic doublet may have a long focal length or infinite focal length (i.e. afocal) at one wavelength to maintain beam collimation. The doublet may be air-spaced and utilize a combination of durable optical glass and crystalline laser materials. In particular with high power lasers and an ultraviolet wavelength, a combination of FS, MGF2, and CAF2 may be used. In combination with the material of the processing lens, two materials can correct or separate focal distances at two wavelengths and three materials can correct or separate focal distances at three wavelengths. To increase the focal distance for example, at 1064 nm relative to a shorter wavelength, the doublet may include a positive element with a relatively high dispersion and a negative element with a relatively low dispersion. For example, the doublet may include a positive FS element and a negative CAF2 element with nearly equal focal lengths. It will be appreciated that more complex chromatic corrector optical designs with more than 2 optical elements may be required for correcting other optical aberrations such as spherical aberration.
[0047] Thereafter the beams 18, 20 are focused by focusing optics 24 to have respective desired beam spot diameters. Delivered to a laser-material interaction zone on the surface of workpiece 22, beams 18, 20 impinge the surface as respective first and second concentric laser spots. In
[0048] The laser spot diameter ratio between beams 18 and 20 is adjusted by configuring chromatic adjuster 16 such that the smaller concentric spot is less than the diameter of the larger concentric spot. The chromatic adjuster may be configured with interchangeable sets of chromatic optics 16 each set defining respective focus distance which are different from one another.
[0049]
[0050] Referring specifically to
[0051] All of the beams are concentric with the outer beam being beam 18 and innermost beam being the third harmonic beam. The collimating optics 26 is placed along the light path downstream form crystal 34 and may be configured as one or more spherical mirrors. The chromatic adjuster 16, as shown is located immediately downstream from collimator 26.
[0052]
[0053] Having described the embodiments of the present invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments. For example, system 10 may be configured with a long pulse IR source with a coaxial, temporally preceding high intensity (ns/ps) pulse of IR/Green/UV/DUV, MM IR beam, with a coaxial single mode IR to create the material state change in the focus, and others. Thus it is understood that various changes, modifications, and adaptations may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.