Low-power MOPA lasers are mainly used for marking, deep engraving, and other applications. Compared to traditional processes, MOPA laser systems offer advantages such as high precision and efficiency. The standout feature of MOPA marking machines, as compared to conventional lasers, is their adjustable pulse width and wide frequency range. With a variety of parameter combinations, MOPA lasers can process various materials with versatile application results. This article mainly introduces the hole drilling applications of the 100W MOPA pulsed fiber laser in the new energy, automotive, hardware, and precision electronics industries, with the aim of providing reference for clients in actual industrial applications.

01 Advantages of Pulsed Laser Drilling and Four Common Drilling Methods

1.1 Four Major Advantages of Pulsed Laser Drilling Compared to Traditional Drilling

Compared to traditional drilling methods, pulsed laser drilling has significant advantages, primarily in four areas:

1. Non-contact: No tool wear and no mechanical stress.
2. Material and Hole Shape Flexibility: Not limited by material type or hole geometry.
3. High Precision and Efficiency: Enables high-quality and fast processing.
4. Flexibility of Equipment: Suitable for automated production lines.

As a result, pulsed laser drilling is widely applied in industries such as precision electronics, aerospace, medical, hardware, and automotive.

1.2 Four Common Pulsed Hole Drilling Methods

The common pulsed laser drilling methods include single-pulse drilling, multi-pulse drilling, ring scanning drilling, and spiral scanning drilling.

• Single-pulse drilling: A single pulse is used to create a molten zone, achieving a high-efficiency result that requires high single-pulse energy.
• Multi-pulse drilling: Multiple pulses with high repetition frequency are applied at the same location to achieve the desired hole.
• Ring scanning drilling: The laser beam follows a circular scanning path on the material to form a hole based on the contour of the material.
• Spiral scanning drilling: The laser beam moves along a spiral trajectory to process the material.

Single and multi-pulse drilling are influenced by the spot shape and focus size, suitable for small holes, efficient, simple to operate, but with lower precision. The ring and spiral scanning methods, which involve rotating the laser beam, are more complex and can create holes of various shapes without being limited by spot size and circularity, allowing for adjustable hole diameters and higher precision.

Pulsed laser drilling is influenced by factors such as average power, pulse width, repetition frequency, single-pulse energy, power density, scanning speed, and line spacing. Among these, pulse width and average power have the most significant impact. Drilling quality is evaluated based on factors such as hole diameter, roundness, spacing, taper, aspect ratio, and edge morphology.

02 100W Pulsed Fiber Laser Drilling Case Studies

2.1 Metal Support Frame Drilling Case

In the new energy sector, a metal support frame with a multi-hole structure is used as a gas transfer channel in hydrogen-oxygen fuel cells. This makes the fuel cell structure more compact.

• Material: 0.5mm thick stainless steel
• Process Parameters: 40% power, 80kHz frequency, 100ns pulse width, multi-pulse drilling method
• Result: 10,000 holes in a 20mm square area, with 0.2mm spacing. Efficiency: 67s. Hole diameter on the front: 40μm, on the back: 12μm. No significant deformation, good hole diameter, small heat-affected zone, and no noticeable splashing.

2.2 Electrode Sheet Drilling Case

In the new energy battery industry, micro-hole arrays are drilled in electrode sheets to increase the contact area of the electrolyte, improving electrolyte infiltration and enhancing battery performance.

• Material: Graphite-metal composite, thickness less than 0.1mm
• Process Parameters: 25% power, 200ns pulse width, 80kHz frequency, multi-pulse drilling method
• Result: Blind holes drilled in the coated area, with depths ranging from 20μm to 40μm and widths between 50μm and 80μm.

2.3 Metal Panel Drilling Case

In the precision electronics industry, micro holes are drilled into stainless steel thin sheets for venting purposes. The consistency of hole diameter is crucial for ensuring stable airflow.

• Material: 50μm thick stainless steel
• Process Parameters: 25% power, 50kHz frequency, 100ns pulse width, multi-pulse drilling method
• Result: 1,141 holes in a 16mm circular area, with a total cycle time of 8s. Front hole diameter: 24μm, back hole diameter: 5μm. No significant deformation, good hole diameter, small heat-affected zone, and no splashing.

2.4 Metal Connector Drilling Case

In the hardware industry, circular holes are drilled in aluminum tubes for component linkage.

• Material: Aluminum tube, outer diameter 19mm, wall thickness 2mm
• Process Parameters: 100% power, 80kHz frequency, 350ns pulse width, spiral scanning method
• Result: Hole diameter: 5mm. Efficiency: 30s per hole. Smooth edges, no burrs, and no damage to the bottom wall.

2.5 Aluminum Alloy Trim Drilling Case

In the automotive industry, micro holes are drilled in aluminum alloy trim pieces for light transmission effects. Dense micro holes are created to achieve various light patterns by controlling hole size and density.

• Material: 0.6mm thick aluminum alloy
• Process Parameters: 80% power, 100ns pulse width, 80kHz frequency, multi-pulse drilling method
• Result: Front hole diameter: approximately 50μm, back hole diameter: approximately 20μm. Hole center spacing: 0.1mm. 10,000 holes drilled in 7s. Smooth surface, no burrs, small heat-affected zone, and no deformation.

03 Summary of Pulsed Laser Drilling Application Processes

The 100W pulsed fiber laser can be used for drilling a wide range of metals and some non-metals. For different metal materials of the same thickness, the drilling results are relatively similar. However, for non-metals such as ceramics, glass, and plastics, the material and thickness have a more significant impact on drilling performance. For holes less than 100μm in diameter, multi-pulse drilling methods are commonly used. For holes larger than 100μm, spiral or ring scanning methods are employed for layer-by-layer material removal to achieve the desired hole.

04 Conclusion

This article primarily introduces the application cases of the 100W MOPA pulsed fiber laser in drilling in various industries. The MOPA pulsed fiber laser has versatile applications and can be used for precision welding, battery cover marking, blackening of steel shell/aluminum anodizing, cutting of brass/aluminum alloy, and oxide layer cleaning.

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