Ultra-short laser pulses are frequently used for material removal (ablation) in science, technology and medicine. However, the laser energy is often used inefficiently, thus, leading to low ablation rates. For the efficient ablation of a rectangular shaped cavity, the numerous process parameters such as scanning speed, distance between scanned lines, and spot size on the sample, have to be optimized. Therefore, finding the optimal set of process parameters is always a time-demanding and challenging task. Clear theoretical understanding of the influence of the process parameters on the material removal rate can improve the efficiency of laser energy utilization and enhance the ablation rate. In this work, a new model of rectangular cavity ablation is introduced. The model takes into account the decrease in ablation threshold, as well as saturation of the ablation depth with increasing number of pulses per spot. Scanning electron microscopy and the stylus profilometry were employed to characterize the ablated depth and evaluate the material removal rate. The numerical modelling showed a good agreement with the experimental results. High speed mimicking of bio-inspired functional surfaces by laser irradiation has been demonstrated.

Ultrashort pulse laser, capable of varying pulse duration between 210 fs and 10 ps and producing a burst of pulses with an intra-burst pulse repetition rate of 64.5 MHz (time distance between pulses 15.5 ns), was used to investigate the ablation efficiency of the copper. The study on ablation efficiency was done for various numbers of pulses per burst between 1 and 40. The increase in the ablation efficiency by 20% for 3 pulses per burst compared to a non-burst regime was observed. The comparison was made between the beam-size optimised regimes. Therefore, the real advantage of the burst regime was demonstrated. To the best of our knowledge, we report the highest laser milling ablation efficiency of copper of 4.84 µm³/µJ by ultrashort pulses at ~1 µm optical wavelength.

Here, to the best of our knowledge, for the first time we report an in-depth experimental study of high ultrafast laser ablation efficiency for processing of copper and steel with single-pulses, MHz, GHz, and burst-in-the-burst (biburst) regimes. The comparison of burst, biburst, and single-pulse ablation efficiencies was performed for beam-size-optimised regimes, showing the real advantages and disadvantages of milling and drilling processing approaches. Highly efficient ultrashort pulse laser processing was achieved for ∼1 µm optical wavelength: 8.8 µm³/µJ for copper drilling, 5.6 µm³/µJ for copper milling, and 6.9 µm³/µJ for steel milling. We believe that the huge experimental data collected in this study will serve well for the better understanding of laser burst-matter interaction and theoretical modelling.

Results on the manipulation of the wetting properties of stainless steel alloy surface by ultrashort pulse laser texturing are presented.