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Holes were percussion drilled in Inconel 718 plates by a high intensity pulsed ultraviolet laser (266 and 355 nm) with 8 ns pulse width. It showed that shortening the laser wavelength resulted in thinner recast layers, less microcracks, and faster machining speed. In order to get high quality and fast speed in laser hole drilling, a two-step processing method was proposed and tested.

Machined feature quality is examined, and the effects of laser pulse width (and thus peak power or intensity) are investigated for the following four laser systems: (1) a millisecond-class, free-running Nd:YAG; (2) a 100-nanosecond-class, Q-switched Nd:YAG laser; (3) a 100-picosecond-class, mode locked Nd:YAG laser; and (4) a 100-femtosecond-class, Ti:sapphire chirped pulse amplification laser. The effect of shorter laser wavelength is also examined by using the second harmonic wavelength of the Nd:YAG laser in the Q-switched and the mode locked pulse formats. Hole drilling and cutting of superalloy, ceramic, and composite materials are studied. The machined feature quality is improved as the pulse width becomes shorter and the peak intensity becomes higher. The shorter wavelength provides another significant improvement. Finally, an attempt is made to view these quality improvements in the context of process throughput and cost of ownership.

We have previously described the drilling of advanced materials such as intermetallics, superalloys, and composites using an Nd:YAG laser operating at the fundamental wavelength of 1.064 μm [1]. We have now extended these studies to the second harmonic wavelength of 532 nm of a high peak power Nd:YAG laser. The results show that drilling using the shorter wavelength further reduces undesired thermal effects such as recast layers and heat affected zones. A comparison of these results with those obtained at the fundamental wavelength is reported.

The quality of laser‐drilled holes is significantly influenced by the laser peak power, pulse format, and wavelength. Three advanced materials are used to demonstrate the importance of choosing the correct laser parameters for a specific material. The materials are: (1) intermetallic single crystal nickel aluminide (NiAl) alloy; (2) N5, a single crystal nickel‐based superalloy; and (3) a silicon carbide (SiC) ceramic matrix composite (CMC). The laser peak power is varied in terms of the pulse duration and format. For low peak powers, long pulse format (pulse lengths on the order of ms), conventional and also shaped‐pulse (burst) commercial rod Nd:YAG laser systems were used. For high peak powers, a short pulse format was adopted for the laser used, namely a cw‐pumped Q‐switched or modelocked/Q‐switched Nd:YAG oscillator followed by a cw‐pumped multipass amplifier using a face‐pumped, total internal reflection Nd:YAG slab as the gain medium. Finally, a KrF excimer laser operating at a 248 nm wavelength was used. The excimer wavelength was chosen to be close to the Nd:YAG fourth harmonic.