Ultrafast laser drilling has been proven to effectively reduce the heat-affected zone (HAZ) of carbon fiber-reinforced polymer (CFRP) composites. However, previous research mainly focused on the effects of picosecond laser parameters on CFRP drilling. Compared with a picosecond laser, a femtosecond laser can achieve higher quality CFRP drilling due to its smaller pulse width, but there are few studies on the effects of femtosecond laser parameters on CFRP drilling. Moreover, the cross-sectional taper of CFRP produced by laser drilling is very large. This paper introduces the use of the femtosecond laser to drill cylindrical holes in CFRP. The effect of laser power, rotational speed of the laser, and number of spiral passes on HAZ and ablation depth in circular laser drilling and spiral laser drilling mode was studied, respectively. It also analyzed the forming process of the drilling depth in the spiral drilling mode and studied the influence of laser energy and drilling feed depth on the holes’ diameters and the taper. The experimental results show that the cylindrical hole of CFRP with a depth-to-diameter ratio of about 3:1 (taper < 0.32${}^{\circ }$, HAZ < 10 m) was obtained by using femtosecond laser and a spiral drilling apparatus.

As an important mid-infrared to far-infrared optical window, ZnS is extremely important to improve spectral transmission performance, especially in the military field. However, on account of the Fresnel reflection at the interface between the air and the high-strength substrate, surface optical loss occurs in the ZnS optical window. In this study, the concave antireflective sub-wavelength structures (ASS) on ZnS have been experimentally investigated to obtain high transmittance in the far-infrared spectral range from 6 μm to 10 μm. We proposed a simple method to fabricate microhole array ASS by femtosecond Bessel beam, which further increased the depth of the microholes and suppressed the thermal effects effectively, including the crack and recast layer of the microhole. The influence of different Gaussian and Bessel beam parameters on the microhole morphology were explored, and three ASS structures with different periods were prepared by the optimized Bessel parameters. Ultimately, the average transmittance of the sample with the ASS microhole array period of 2.6 μm increased by 4.1% in the 6 μm to 10 μm waveband, and the transmittance was increased by 5.7% at wavelength of 7.2 μm.

Laser scribing in chemical milling is an important process which can effectively improve the precision and efficiency of chemical milling, and is of great significance to improve the thrust–weight ratio and manufacturing efficiency of aviation and aerospace parts. According to the scribing requirements in chemical milling for aviation and aerospace parts, the process and mechanism of laser scribing were studied and the influence of different process parameters for the quality of laser scribing was analyzed. Based on the review of related research literature, the laser scribing process, the ablation mechanism and technology of different materials and the selective laser removal process for “laser–coating–substrate” are summarized and discussed. Based on the requirements of high-precision laser scribing on complex surfaces, the current situation of laser scribing equipment is summarized. Finally, the practical challenges and key technical problems for the laser scribing process are summarized, and the application and development of laser scribing in aerospace manufacturing are prospected.

An effective and simple method is proposed for fabricating the micro/nano hybrid structures on metal surfaces by adjusting femtosecond laser fluence, scanning interval, and polarization. The evolution of surface morphology with the micro/nano structures is discussed in detail. Also, the mechanism of light absorption by the micro/nano hybrid structures is revealed. Compared with the typical periodic light-absorbing structures, this type of micro/nano hybrid structures has an ultralow average reflectivity of 2% in the 250–2300 nm spectral band and the minimum 1.5% reflectivity in UV band. By employing this method, large areas of the micro/nano hybrid structures with high consistency could be achieved.

Enhancing the infrared window transmittance of zinc sulfide (ZnS) is important to improve the performance of infrared detector systems. In this work, a new hybrid micro/nanostructure was fabricated by an optimal Bessel femtosecond laser on ZnS substrate. The surface morphologies and profiles of ASS ablated by a 20× microscope objective Bessel beam are described, indicating that the nanoripples on the micropore were formed by the SPP interference and the SPP scattering in a particular direction. Further, the maximum average transmittance of ASS increased by 9.7% and 12.3% in the wavelength ranges of 5~12 μm and 8~12 μm, respectively. Finally, the antireflective mechanism of the hybrid micro/nanostructure is explored using the novel electromagnetic field model based on the FDTD method, and we attribute the stable antireflective performance of ASS in broadband to the interface effective dielectric effect and LLFE.

Laser fabrication of metallic superhydrophobic surfaces (SHSs) for anti-frosting has recently attracted considerable attention. Effective anti-frosting SHSs require the efficient removal of condensed microdroplets through self-propelled droplet jumping, which is strongly influenced by the surface morphology. However, detailed analyses of the condensate self-removal capability of laser-structured surfaces are limited, and guidelines for laser processing parameter control for fabricating rationally structured SHSs for anti-frosting have not yet been established. Herein, a series of nanostructured copper-zinc alloy SHSs are facilely constructed through ultrafast laser processing. The surface morphology can be properly tuned by adjusting the laser processing parameters. The relationship between the surface morphologies and condensate self-removal capability is investigated, and a guideline for laser processing parameterization for fabricating optimal anti-frosting SHSs is established. After 120 min of the frosting test, the optimized surface exhibits less than 70% frost coverage because the remarkably enhanced condensate self-removal capability reduces the water accumulation amount and frost propagation speed (<1 μm/s). Additionally, the material adaptability of the proposed technique is validated by extending this methodology to other metals and metal alloys. This study provides valuable and instructive insights into the design and optimization of metallic anti-frosting SHSs by ultrafast laser processing.