In this contribution, we report on a laser-chemical removal method for precise machining of micro forming tools.
Thereby, a focused machining laser beam is guided coaxially to an etchant jet stream. Since the material removal is
caused by laser-induced chemical reactions using this method, machining is achieved at low laser powers. Hence,
material stressing involving micro cracks and further parasitic effects can be avoided. Due to these advantages, this
method offers a suitable technique for the finishing of precision micro tools. Several experiments have been performed at
rotary swaging jaws made of Stellite 21 in order to chamfer the edged transition section between the operating sphere
and the tool flank. The influence of both different laser powers and work piece traverse speeds has been investigated. For
this purpose, several parallel laser paths were applied along the edged transition section when varying the process
parameters. Here, the incident laser beam is subjected to different angles of incidence. Due to reflection effects, the
process parameters have to be matched with respect to the particular angle of incidence during the machining. In this
vein, the edged transition section of rotary swaging jaws was chamfered at radii in the range of 120 μm.
In this paper we report on a new method for the generation of shaped holes by dynamical variation of the beam shape with a special optical system. It is based on using a q-switched Nd:YAG laser with 100 ns pulses at a wavelength of 1064 nm and an optical setup producing a photon tube. By variation of the beam divergence the shape of the photon tube can be variably modified. The optical system consists of a specially designed Galilean telescope and a focusing objective. The beam divergence can be changed in-situ by the Galilean telescope while processing. This enables to control diameter, length and angle of the photon tube. Shaped controlled structures are processed applying in-situ different optical fields which have been previously defined by simulations including aberrations and diffraction effects. As an example, the variable beam shaping resulted in through-going cylindrical bores as well as such ones with a defined conical inlet with respect to its taper angle and depth. Taper angles between 1 and nearly 50 degrees were realized by varying both the beam divergence and laser power. Furthermore, the variable beam shaping leads to improved and almost debris-free machining efficiency.
Laser-induced technological chemical processes can significantly contribute to the development of new methods for micro treatment of materials and hence to the broadening of the application spectrum of laser microtechnology. In this paper three typical laser-activated chemical technological methods in liquids, gases and solids and their possible applications are presented and discussed: (1) Laser-induced liquid-phase jet-chemical etching of metals. In this method, laser radiation which is guided from a coaxially expanding liquid jet-stream initiates locally on a metal surface a thermochemical etching reaction, which leads to a selective material removal at high resolution (<1 μm) and quality of the treated surface; (2) Local photon-plasma induced synthesis of thin film coatings. This technological method is based on thermochemical CVD processes taking place in a photon-initiated stationary plasma maintained in the electromagnetic optical field of a high-power cw-CO2 laser radiation. This method allows synthesis of thin-film coatings in the open-air atmosphere without using vacuum or reaction chamber; (3) Laser-induced photochemical modification of the optical properties of polymers. This method is based on the local controllable change of the polymer structure leading to modification of the refractive index in the treated area. By numerous independently adjustable laser radiation parameters, for instance wavelength and irradiation dose, the modification process can be controllably driven in order to generate desired functional properties.
In this treatment method laser radiation, which is guided from a coaxially expanding liquid jet-stream, locally initiates a thermochemical etching reaction on a metal surface, which leads to selective material removal at high resolution and quality of the treated surface as well as low thermal influence on the workpiece. Electrochemical investigations were performed under focused laser irradiation using a cw-Nd:YAG laser with a maximum power of 15 W and a simultaneous impact of the liquid jet-stream consisting of phosphoric acid with a maximum flow rate of 20 m/s. The time resolved measurements of the electrical potential difference against an electrochemical reference electrode were correlated with the specific processing parameters and corresponding etch rates to identify processing conditions for temporally stable and enhanced chemical etching reactions. Applications of laser-induced liquid-phase jet-chemical etching in the field of sensor technology, micromechanics and micrmoulding technology are presented. This includes the microstructuring of thin film systems, cutting of foils of shape memory alloys or the generation of structures with defined shape in bulk material.
Laser-induced technological chemical processes can significantly contribute to the development of new methods for micro treatment of materials and hence to the broadening of the application spectrum of laser microtechnology. In this paper three typical laser-activated chemical technological methods in liquids, gases and solids and their possible applications are presented and discussed: 1) Laser-induced liquid-phase jet-chemical etching of metals. In this method, laser radiation which is guided from a co-axially expanding liquid jet-stream initiates locally on a metal surface a thermochemical etching reaction, which leads to a selective material removal at high resolution (<1μm) and quality of the treated surface; 2) Local photon-plasma induced synthesis of thin film coatings. This technological method is based on thermochemical CVD processes taking place in a photon-initiated stationary plasma maintained in the electromagnetic optical field of a high-power cw-CO2 laser radiation. This method allows synthesis of thin-film coatings in the open-air atmosphere without using vacuum or reaction chamber; 3) Laser-induced photochemical modification of the optical properties of polymers. This method is based on the local controllable change of the polymer structure leading to modification of the refractive index in the treated area. By numerous independently adjustable laser radiation parameters, for instance wavelength and irradiation dose, the modification process can be controllably driven in order to generate desired functional properties.
In the following, three different laser-assisted processes are described and herewith produced components in the fields of micromechanics are presented. First, excimer laser projection technology is modified in order to produce large- area microstructures. It enables the transfers of structures having dimensions much larger than the laser beam section by synchronized scanning of the mask and the substrate. This technology is used to manufacture master structures in polymers for injection molding inserts. The insert tool itself is produced by electroforming of the master leading to metallic copy of the master. In this way, a metallic insert tool is performed for the production of microfluidic components. Its structured area is 2 cm2 at a resolution better than 3 micrometers . Second, laser-induce wet chemical etching using a sw-Nd:YAG laser is described. The principle of this micromachining method is based on a local thermal activation of chemical etching reactions on the surface of the material. The direct processing of the workpiece resulted in high accuracy microstructuring with smooth surfaces and without any debris or thermal influence on the material properties. Among others, one example in the field of application in micromechanics is the fabrication of superelastic micro-grippers prepared by cutting of temperature sensitive shape memory alloys. The achieved sidewall angle is about 3 degrees and the surface roughness less than 0.4 micrometers for machined 200 micrometers thick foils. Third, a combination of the two afore mentioned processes leads to complex shaped microstructures in metallic parts. Thereby, additional microstructures of specific shape, e.g. V-shaped grooves, are machined by laser-induced wet chemical etching into metallic inserts produced by electroforming of excimer laser-induced wet chemical etching into metallic inserts produce by electroforming of excimer laser machined masters. They are used for hot embossing tools enabling the production of special housings which can be hermetically sealed by ultrasonic welding.
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