Multiple-pulse laser dynamic forming of metallic thin films for microscale three dimensional shapes

Laser dynamic forming (LDF) is a novel high energy rate microfabrication technique, which makes use of the shock pressure induced by laser to generate dynamic high strain rate three dimensional (3D) forming of thin films. In LDF process, a high shock pressure accelerates the workpiece to a high velocity and deforms it into complex 3D shapes. The forming velocity of the workpiece imparted by a single laser pulse with high energy may exceed the critical forming velocity of the material, and thus causing it to fracture. This problem is more severe when 3D structure of large aspect ratio needs to be formed. To overcome this problem, multiple-pulse LDF is investigated in this study. The total laser energy is evenly distributed in different laser pulses to keep the forming velocity below the critical forming velocity of the material. The effects of the multiple-pulse LDF on the deformation behavior of ultrathin foils are investigated. The deformation depth and thickness variation distribution of the formed 3D features are characterized to reveal these effects. In addition, the effects of vacuum conditions on multiple-pulse LDF process are carried out. It is found that the bounce off of the foil can be effectively reduced by multiple-pulse LDF and the final shape could be controlled much more accurately. By extending single pulse LDF to multiple-pulse LDF, the forming capability of LDF is further enhanced, and thus enlarges the applicable range of this technique. (C) 2010 American Institute of Physics. [doi: 10.1063/1.3457869]