Interaction of a Nd:YAG laser, operating at wavelengths of 1064 nm (23.6 J cm−2 fluence) or 532 nm (25.9 J cm−2 fluence), and pulse duration of 40 ps, with a titanium-based medical implant Ti6Al4V alloy was studied. Surface damage thresholds were estimated to be 0.9 J cm−2 and 0.25 J cm−2 at laser wavelengths 1064 nm and 532 nm, respectively. At both laser wavelengths, the energy absorbed was mostly converted into thermal energy, forming craters, albeit about 50 times deeper at 1064 nm than at 532 nm. Periodic surface structures (PSS) were also formed with both laser wavelengths, concentric, and radial at micrometer scale (3 µm to 15 µm period), parallel at nanometer scale (800 nm period with the 1064 nm laser, 400 nm with the 532 nm laser). In the case of the 532 nm laser, the concentric structures enlarge their period with accumulating laser pulse count. These features can help roughening of the implant surface and improve bio-compatibility.

This paper presents an experimental study carried out on Nimonic 263 alloy sheets to determine the optimal combination of laser cutting control factors (assisted gas pressure, beam focus position, laser power, and cutting speed), with respect to multiple characteristics of the cut area. With the aim of designing laser cutting parameters that satisfy the specifications of multiple responses, an advanced multiresponse optimization methodology was used. After the processing of experimental data to develop the process measure using statistical methods, the functional relationship between cutting parameters and the process measure was determined by artificial neural networks (ANNs). Using the trained ANN model, particle swarm optimization (PSO) was employed to find the optimal values of laser cutting parameters. Since the effectiveness of PSO could be affected by its parameter tuning, the settings of PSO algorithm-specific parameters were analyzed in detail. The optimal laser cutting parameters proposed by PSO were implemented in the validation run, showing the superior cut characteristics produced by the optimized parameters and proving the efficacy of the suggested approach in practice. In particular, it is demonstrated that the quality of the Nimonic 263 cut area and the microstructure were significantly improved, as well as the mechanical characteristics.