Professional Documents
Culture Documents
https://doi.org/10.1007/s00170-022-10120-7
ORIGINAL ARTICLE
Received: 6 April 2022 / Accepted: 6 September 2022 / Published online: 12 September 2022
© The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature 2022
Abstract
Optical interference caused by gas bubbles in water is of prime concern in underwater laser micromachining process since
it importantly affects the quality of laser-ablated surface and material removal rate. This study applied positive water pres-
sure in the underwater laser ablation with the attempts to reduce the bubble size, minimize the optical disturbance to the
laser beam in water, and promote the cut quality. A nanosecond pulse laser was used for grooving a single-crystalline silicon
wafer in a pressurized water environment. The effects of water pressure and average laser power on groove width, groove
depth, size of heat-affected zone, and cut surface morphology were examined and discussed together with the analysis of
laser beam refraction in water. The results revealed that the higher the water pressure, the cleaner the cut surface, and smaller
heat-affected zone and higher aspect ratio of groove were obtained. The ablation technique proposed in this paper could
be a promising method for scribing silicon and plausibly other semiconductor materials at high removal rate with high cut
quality and negligible damage.
13
Vol.:(0123456789)
3162 The International Journal of Advanced Manufacturing Technology (2022) 122:3161–3169
too low temperature, the laser-irradiated material is hardly interactions, roles of water pressure, and removal mecha-
vaporized from the work surface, and this in turn decreases nism in the underwater laser micromachining process.
the material removal rate. The microjets formed during the
laser ablation in water can cause the mechanical shock pres-
sure in the order of 1.7 ± 0.3 GPa [7], and this can assist the 2 Materials and methods
removal of molten and cut debris from the laser-ablated area.
In addition to the microjet formation, the use of ultrasound Single-crystalline silicon was selected as a work sample in this
can energize water during the laser ablation. This technique study since it has widely been used in micro-components and
is able to enhance the material removal performance and semiconductor devices. A nanosecond pulse laser (IPG YLP-
diminish the deposition of cut debris as well as cavitation 1–100-30–30, Germany) emitting a wavelength of 1064 nm was
bubbles on the work surface through the ultrasonic cleaning applied for grooving a silicon wafer. The laser machine used
mechanism [8–11]. in this work provided the maximum average power of 30 W,
A crucial limitation of underwater laser ablation is the pulse duration of 100 ns, and pulse repetition rate of 30 kHz. A
presence of gas bubbles generated during the process. The collimated laser beam with Gaussian distribution was focused
bubbles are induced by the vaporization of water and work by a 254-mm f-theta lens. The focused laser beam was scanned
material, and the bubble size is subject to laser energy and on the workpiece surface with a single straight line at a traverse
thermal properties of work material [2, 3]. These bubbles speed of 1 mm/s for producing a groove. The whole sample was
significantly cause optical disturbances to the incident laser clamped inside a water chamber as shown in Fig. 1. Water was
beam by means of reflection and refraction [12], thus dete- pumped into the chamber and directionally flowed across the
riorating the laser beam quality for the ablation. By flowing workpiece surface at a constant rate of 4 l/min. The top side
water across the workpiece surface in the underwater laser of chamber had a 10-mm-thick fused silica window, allowing
ablation, the bubbles adhering to the work surface can be the incident laser beam to reach the work surface for ablation.
flushed away [6, 13, 14]. However, new bubbles are repeat- The distance between the back side of window and workpiece
edly formed after each laser pulse and some can coalesce surface was 1.0 mm, where the heat convection and flushing
to be a larger bubble [3]. This makes it difficult to blow all of cut debris took place during the ablation. The focused beam
of them at all times throughout the laser micromachining diameter after passing through the glass window and water
process in water. Although using a higher water flow rate layer was 68.81 μm.
is possible to blow the bubbles away from the workpiece Four different levels of water pressure, i.e., 10, 20, 30, and
surface, the significant heat loss due to the forced convec- 40 bar were tested in this study to understand its influence
tion importantly reduces the material removal rate, hence on the groove width, groove depth, width of heat-affected
requiring a higher laser power to compromise this tradeoff. zone (HAZ), and cut surface morphology. The width of HAZ
Instead of blowing off the bubbles, they can be atomized by was taken from the edge of groove to the boundary of recast
ultrasound in the ultrasonic-assisted underwater laser abla- or spatter deposition zone. In addition to the water pressure,
tion [10]. However, the amount of tiny bubbles suspending three levels of average laser power were examined in this
in water turns to increase, and this can adversely scatter the work as listed in Table 1. The selection of these processing
incident laser beam in water to some extent. conditions was based on a number of preliminary tests and
Another technique to minimize the bubble size and to our previous studies [5, 6]. The experiment was designed
diminish the laser beam disturbance in water is to increase with regard to the full-factorial scheme, and the number of
the static pressure of water around the bubbles [15]. The experimental runs was 12 with three replications. Each cut
higher the pressure, the smaller the bubble is formed [16]. Li sample was observed by a scanning electron microscope
et al. [17] noted that the bubble size in water can be reduced (Hitachi SU3900 Series, Japan). The groove width, groove
by 50.3% when the positive pressure of 3.5 bar is applied.
The reduction of bubble size reduces the chance of bub-
bles to interfere with the incident laser beam in water, thus Laser
minimizing the optical disturbances. By applying high water
pressure in the underwater laser ablation, the gas bubbles Workpiece
caused by the vaporization could be smaller and/or of less
amount than the typical underwater technique. According Water out 1.0 mm Water in
to the best of our knowledge and literature search, there has 4 l/min
been no study investigating the effect of water pressure on Fixture
the ablation performance in the underwater laser microma-
chining process. This paper therefore aims at this investiga- Fig. 1 Schematic of experimental setup for the underwater laser
tion to better the understanding of laser-water-work material micromachining process
13
The International Journal of Advanced Manufacturing Technology (2022) 122:3161–3169 3163
13
3164 The International Journal of Advanced Manufacturing Technology (2022) 122:3161–3169
Fig. 2 Grooves obtained after the laser ablation in water under the pressure of a, c 10 and b, d 40 bar and average laser power of a, b 20 and c, d 30 W
13
The International Journal of Advanced Manufacturing Technology (2022) 122:3161–3169 3165
Fig. 3 Optical interaction
between laser and gas bub-
ble formed under the different
levels of water pressure
Since the collapsing is very dynamic, the size, shape, and the change of average laser power significantly changed the
location of bubbles are difficult to be predicted by the ana- sizes of groove and HAZ (p-value < 0.05), whereas only the
lytical approach. However, the bubble size and lifetime are groove depth and width of HAZ were affected by the change
anticipated to be decreased under the high-pressure environ- of water pressure. This implies that using high water pres-
ment [17], and this is affirmed by our findings through the sure can facilitate the increased groove depth and reduced
analyses of optical refraction and groove surface quality. HAZ without significantly enlarging the groove width. A
The interference of bubbles to the laser beam in water can high aspect ratio of groove was thereby achievable when
therefore be kept at minimum, and a better cut surface qual- ablating silicon in the pressurized water.
ity is achievable compared to the typical underwater laser The average value and standard deviation of groove width,
micromachining process. groove depth, and HAZ width obtained under the different
In addition to the quality of groove surface, the width and processing conditions are plotted in Fig. 5a–c. The aspect
depth of groove as well as the width of heat-affected zone ratio of groove was calculated by dividing the width into
(HAZ) were quantified in this study. Analysis of variance the depth, and it is plotted in Fig. 5d. The results showed
(ANOVA) was applied to statistically determine the signifi- that a large and deep groove was produced by using high
cance of the tested parameters towards the groove dimen- laser power. The width of HAZ also increased with the
sions and size of HAZ, and the ANOVA results for these average laser power applied in the ablation. This is associ-
responses are listed in Table 2. The results indicated that ated with the high heat energy that melts and vaporizes the
13
3166 The International Journal of Advanced Manufacturing Technology (2022) 122:3161–3169
Table 2 Analysis of variance results for groove width, groove depth, and width of heat-affected zone
Source DF Groove width Groove depth Width of heat-affected zone
Adj SS Adj MS P-value Adj SS Adj MS P-value Adj SS Adj MS P-value
Model 5 2979.93 595.99 0.013 25,745.1 5149.0 0.000 620.41 124.082 0.003
Linear 5 2979.93 595.99 0.013 25,745.1 5149.0 0.000 620.41 124.082 0.003
Water pressure 3 43.00 14.33 0.901 2816.0 938.7 0.003 489.56 163.185 0.002
Laser power 2 2936.93 1468.46 0.002 22,929.1 11,464.6 0.000 130.85 65.426 0.023
Error 6 459.68 76.61 336.4 56.1 52.29 8.716
Total 11 3439.60 26,081.5 672.70
S = 8.75290, R-sq(adj) = 75.50% S = 7.48761, R-sq(adj) = 97.64% S = 2.95224, R-sq(adj) = 85.75%,
DF degree of freedom, Adj SS adjusted sum of squares, Adj MS adjusted mean squares, P-value a probability that measures the evidence against
the null hypothesis, S standard deviation, R-sq(adj) adjusted R-sq
laser-irradiated material in a large area. A large groove with bubble size is shrunk and small enough to not interfere with
large HAZ is thereby obtained as a result. When a higher or impede the incident laser beam in water. This thus allows
water pressure was employed, the size of gas bubbles and the laser beam to maintain its focusing position and quality
laser scattering in water was reduced. This allows the laser for deepening the groove. However, the threshold of 20 bar
beam to travel in water and reach the workpiece surface with is only valid for the laser traverse speed of 1 mm/s and laser
less scattering by the bubbles. The contribution of water pres- pulse repetition rate of 30 kHz tested in this study. Since the
sure towards the material removal rate was discernable when incident angle of laser at the bubble surface (θw) is a func-
the applied pressure was equal to or greater than 20 bar at tion of v and f as noted in Eqs. (3 and 4), the threshold could
which the groove depth substantially increased. Based on be lower than 20 bar when using higher laser traverse speed
the compression of gas bubbles under the high static pres- or lower pulse repetition rate at which the distance between
sure and the analysis of optical refraction described earlier, the consecutive laser pulses (xn) is larger than the bubble
the water pressure of 20 bar could be a threshold where the radius (Rb). When the water pressure was greater than the
160
depth; c width of heat-affected 80
zone; d aspect ratio of groove 120
60
80
40
80 2
Average laser power (W) 1.8
Width of heat-affected zone (μm)
20 25 30 1.6
Aspect ratio of groove
60
1.4
1.2
40 1
0.8
0.6
20
0.4
Average laser power (W)
0.2 20 25 30
0 0
0 10 20 30 40 50 0 10 20 30 40 50
(c) Water pressure (bar) (d) Water pressure (bar)
13
The International Journal of Advanced Manufacturing Technology (2022) 122:3161–3169 3167
Depth (µm)
Depth (µm)
sure; b 20-W laser power with -100 -100
40-bar water pressure; c 30-W
laser power with 10-bar water -150 -150
pressure; d 30-W laser power
-200 -200
with 40-bar water pressure
Laser power: 20 W Laser power: 20 W
-250 -250
Water pressure: 10 bar Water pressure: 40 bar
-300 -300
0 150 300 450 600 0 150 300 450 600
(a) Distance (µm) (b) Distance (µm)
0 0
-50 -50
Depth (µm)
Depth (µm)
-100 -100
-150 -150
-200 -200
Laser power: 30 W Laser power: 30 W
-250 -250
Water pressure: 10 bar Water pressure: 40 bar
-300 -300
0 150 300 450 600 0 150 300 450 600
(c) Distance (µm) (d) Distance (µm)
(a)
(b)
Fig. 7 EDS spectrum of grooves produced by using the average laser power of 30 W and water pressure of (1) 10 bar and (2) 40 bar
13
3168 The International Journal of Advanced Manufacturing Technology (2022) 122:3161–3169
threshold of 20 bar, there was no significant improvement ther be reduced by using high laser traverse speed and/
for the groove depth as shown in Fig. 5b. This is plausibly or low laser pulse repetition rate.
because the process already reaches the status of no bubble 3. Recast depositing on and nearby the groove was found
disturbance, so that the laser can perform its maximum capa- to be minimum when the ablation was performed in the
bility for the ablation in water. pressurized water. EDS spectrums revealed low oxy-
As per the results shown in Fig. 5d, the highest aspect gen peak on the groove surface produced by the aid of
ratio of groove is 1.7 when using the average laser power 40-bar water pressure. This could be implied that the
of 30 W and water pressure of 40 bar. Under this condition, oxidized recast was less when the high water pressure
the width of HAZ was only 26 μm which was smaller than was applied.
that of 10-bar condition by 36%. Some samples of groove 4. The findings of this work have brought another new
profile caused by using the different processing conditions micromachining technique and its potential to improve
are depicted in Fig. 6, noting that the groove in silicon is the cut quality and material removal rate by applying
substantially deeper when applying higher water pressure in high water pressure to the underwater laser microma-
the underwater laser micromachining process. chining process. The proposed technique could be a
Energy-dispersive X-ray spectroscopy (EDS) was also promising method for scribing silicon and possibly other
used in this study to detect and compare chemical composi- materials at high removal rate with high cut quality and
tion on the groove surface produced by using the 30-W laser less damage.
ablation at 10- and 40-bar water pressures. The EDS spec-
trums are shown in Fig. 7, noting that the peak of oxygen
is low when ablating silicon under the high water pressure. Author contribution Wisan Charee: conceptualization, methodol-
ogy, investigation, formal analysis, validation, visualization, writing
A greater amount of oxygen detected on the laser-ablated — original draft preparation. Huan Qi: validation, writing — review
surface could imply a more amount of oxidized recast on the and editing. Viboon Saetang: conceptualization, methodology, formal
surface. According to these results, the groove surface qual- analysis, writing — review and editing, supervision.
ity and removal rate of silicon were significantly improved
with negligible damage when the laser micromachining pro- Funding The Rajamangala University of Technology Isan (No.
SKC2562REV114); National Key Research and Development Pro-
cess was performed in the pressurized water. gram of China (No. 2021YFE0110300); Thailand Science Research
and Innovation (TSRI) under Fundamental Fund 2022 (Project:
Advanced Materials and Manufacturing for Applications in New
4 Conclusions S-curve Industries)”.
13
The International Journal of Advanced Manufacturing Technology (2022) 122:3161–3169 3169
Advanced Manufacturing Technology 107(5):2333–2344. https:// 14. Wang X, Huang Y, Xu B, Xing Y, Kang M (2019) Comparative
doi.org/10.1007/s00170-020-05182-4 assessment of picosecond laser induced plasma micromachining
6. Charee W, Tangwarodomnukun V, Dumkum C (2015) Laser abla- using still and flowing water. Opt Laser Technol 119:105623.
tion of silicon in water under different flow rates. Int J Adv Manuf https://doi.org/10.1016/j.optlastec.2019.105623
Technol 78(1):19–29. https://d oi.o rg/1 0.1 007/s 00170-0 14-6 625-6 15. Pan Y, Hou Z, Qu N (2019) Improvement in accuracy of micro-
7. Nguyen TTP, Tanabe R, Ito Y (2014) Effects of an absorptive dimple arrays prepared by micro-electrochemical machining with
coating on the dynamics of underwater laser-induced shock pro- high-pressure hydrostatic electrolyte. The International Journal of
cess. Appl Phys A Mater Sci Process 116(3):1109–1117. https:// Advanced Manufacturing Technology 100(5):1767–1777. https://
doi.org/10.1007/s00339-013-8193-2 doi.org/10.1007/s00170-018-2822-z
8. Kang B, Woo Kim G, Yang M, Cho SH, Park JK (2012) A study 16. Martí-López L, Ocaña R, Piñeiro E, Asensio A (2011) Laser peen-
on the effect of ultrasonic vibration in nanosecond laser machin- ing induced shock waves and cavitation bubbles in water studied
ing. Opt Lasers Eng 50(12):1817–1822. https://d oi.org/10.1 016/j. by optical schlieren visualization. In: Physics Procedia 442–451.
optlaseng.2012.06.013 https://doi.org/10.1016/j.phpro.2011.03.055
9. Wang H, Zhu S, Xu G, Zhou W, Li L, Zhang DH, Ren N, Xia 17. Li B-b, Zhang H-c, Lu J, Ni X-w (2011) Experimental investiga-
K, Shi C (2018) Influence of ultrasonic vibration on percussion tion of the effect of ambient pressure on laser-induced bubble
drilling performance for millisecond pulsed Nd:YAG laser. Opt dynamics. Opt Laser Technol 43(8):1499–1503. https://doi.org/
Laser Technol 104:133–139. https://doi.org/10.1016/j.optlastec. 10.1016/j.optlastec.2011.05.016
2018.02.023 18. Wuttisarn T, Tangwarodomnukun V, Dumkum C (2020) Laser
10. Zhou J, Xu R, Jiao H, Bao J-d, Liu Q-y, Long Y-h (2020) Study micromachining of titanium alloy in water and ice at different
on the mechanism of ultrasonic-assisted water confined laser temperatures. Opt Laser Technol 125:106024. https://doi.org/10.
micromachining of silicon. Opt Lasers Eng 132:106118. https:// 1016/j.optlastec.2019.106024
doi.org/10.1016/j.optlaseng.2020.106118 19. Zheng C, Shen H (2022) Ablation mechanism in underwater drill-
11. Sun X, Zhou J, Duan J-A, Du H, Cui D, Hu Y (2018) Experi- ing by an ultrafast laser with pulse energy below the water break-
mental research on ultrasound-assisted underwater femtosecond down threshold. J Manuf Process 73:354–363. https://doi.org/10.
laser drilling. Laser Part Beams 36(4):487–493. https://doi.org/ 1016/j.jmapro.2021.11.020
10.1017/s0263034618000538
12. Zhang D, Gökce B, Sommer S, Streubel R, Barcikowski S (2016) Publisher's Note Springer Nature remains neutral with regard to
Debris-free rear-side picosecond laser ablation of thin germanium jurisdictional claims in published maps and institutional affiliations.
wafers in water with ethanol. Appl Surf Sci 367:222–230. https://
doi.org/10.1016/j.apsusc.2016.01.071 Springer Nature or its licensor holds exclusive rights to this article under
13. Feng W, Guo J, Yan W, Wan YC, Zheng H (2019) Deep channel a publishing agreement with the author(s) or other rightsholder(s);
fabrication on copper by multi-scan underwater laser machining. author self-archiving of the accepted manuscript version of this article
Opt Laser Technol 111:653–663. https://doi.org/10.1016/j.optlastec. is solely governed by the terms of such publishing agreement and
2018.10.046 applicable law.
13