Characteristics and homogenization removal methods of ultraviolet femtosecond laser processing of aerospace AFRP
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摘要:
针对Kevlar 49/4211芳纶纤维/环氧树脂复合材料的紫外飞秒激光（343 nm，260 fs）加工阈值和形貌特性进行研究。通过面积外延法测算了芳纶纤维增强树脂基复合材料(AFRP)中树脂基体、增强纤维及复合材料整体的激光去除阈值及阈值孵化效应，并预测三者的单脉冲去除阈值；分析入射能量通量与等效入射激光脉冲数量对材料加工边缘质量的影响规律。结果表明：Kevlar 49芳纶纤维的紫外飞秒激光去除阈值和阈值孵化系数在不同脉冲数作用下均低于 4211环氧树脂，AFRP整体的等效去除阈值介于树脂和芳纶纤维之间。选择4211环氧树脂阈值若干倍的入射通量与100个以上等效脉冲数的紫外飞秒激光，采用原位叩击打孔或循环扫描切割的方法，能够获得入口宽度均匀、边缘整齐、材料准均质化去除的加工形貌，从而有效提高航天AFRP产品的加工精度与质量，满足其高性能制造需求。
Abstract:The UV femtosecond laser (343 nm, 260 fs) processing threshold and morphology characteristics of Kevlar 49/4211 aramid fiber/epoxy resin composite materials were studied. The area epitaxy method was used to calculate the laser removal threshold and threshold incubation effect of resin matrix, reinforced fibers, and the overall composite material in aramid fiber reinforced polymer (AFRP). The single pulse removal thresholds of the three were predicted; the impact of incident energy flux and equivalent number of input laser pulses on the quality of material processing edges was examined. The results showed that the UV femtosecond laser removal threshold and threshold incubation coefficient of Kevlar 49 aramid fiber were lower than those of 4211 epoxy resin under different pulse numbers, and the overall equivalent removal threshold of AFRP was between resin and aramid fiber. A processing morphology with uniform inlet width, neat edges, and quasi-homogeneous material removal can be achieved by choosing a UV femtosecond laser with an incident flux several times the threshold of 4211 epoxy resin and more than 100 equivalent pulse numbers and employing in-situ tapping or cyclic scanning cutting techniques. This effectively improves the processing accuracy and quality of aerospace AFRP products and satisfies their high-performance manufacturing needs.
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图 4 Kevlar 49/4211复合材料实验试片
Figure 4. Kevlar 49/4211 composite material experimental specimen
图 5 紫外飞秒激光加工系统示意图
Figure 5. Schematic diagram of ultraviolet femtosecond laser processing system
图 7 4211环氧树脂在不同激光入射能量和入射脉冲数作用下的烧蚀坑
Figure 7. Erosion pits of 4211 epoxy resin under different laser incident energies and incident pulse numbers
图 8 4211环氧树脂在不同脉冲数作用下的烧蚀坑直径平方D2与入射通量F0关系
Figure 8. Relationship between square of ablation pit diameter (D2) and incident flux (F0) of 4211 epoxy resin under different pulse numbers
图 9 4211环氧树脂去除阈值随激光入射脉冲数变化规律
Figure 9. Variation law of 4211 epoxy resin removal threshold with number of laser incident pulses
图 10 NFth(N)随入射脉冲数目N的变化关系
Figure 10. Relationship between NFth (N) and number of incident pulses N
图 11 Kevlar 49芳纶纤维在紫外飞秒激光原位叩击时的烧蚀形貌
Figure 11. Ablation morphology of Kevlar 49 aramid fibers during in-situ impact of ultraviolet femtosecond laser
图 12 紫外飞秒脉冲作用下Kevlar 49芳纶纤维材料的烧蚀坑直径平方与入射通量关系
Figure 12. Relationship between square of ablation pit diameter and incident flux of Kevlar 49 aramid fiber material under action of ultraviolet femtosecond pulses
图 13 紫外飞秒激光作用下Kevlar 49芳纶纤维的去除阈值孵化效应
Figure 13. Incubation effect of removal threshold on Kevlar 49 aramid fiber under UV femtosecond laser irradiation
图 14 Kevlar 49/4211 AFRP在紫外飞秒激光原位叩击时的烧蚀形貌
Figure 14. Ablation morphology of Kevlar 49/4211 AFRP during in situ impact of ultraviolet femtosecond laser
图 17 Kevlar 49/4211 AFRP复合材料在紫外飞秒激光作用下各个组分的阈值对比
Figure 17. Comparison of thresholds for various components of Kevlar 49/4211 AFRP composite materials under UV femtosecond laser irradiation
图 18 4211环氧树脂与Kevlar 49芳纶纤维在紫外飞秒激光作用下的阈值孵化曲线
Figure 18. Threshold incubation curves of 4211 epoxy resin and Kevlar 49 aramid fibers under UV femtosecond laser irradiation
图 19 Kevlar 49/4211在100个脉冲原位叩击下的去除效果
Figure 19. Removal effect of Kevlar 49/4211 under 100 pulse in situ percussion
图 20 AFRP在100等效脉冲作用下的扫描刻蚀效果
Figure 20. Scanning etching effect of AFRP under 100 equivalent pulses
图 21 100个等效紫外飞秒激光脉冲切割AFRP的切口剖面
Figure 21. 100 equivalent ultraviolet femtosecond laser pulses for cutting kerf profiles of AFRP
图 22 紫外飞秒激光在AFRP层合板上切割的通孔
Figure 22. Through holes cut by ultraviolet femtosecond laser on AFRP laminates
表 1 激光器基本参数
Table 1. Basic parameters of laser
平均功率P/W 脉冲重复频率fc/kHz 脉冲宽度(半高全宽)/fs 波长λ/nm 0.01～20 1～ 1000 260 343 
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表 2 4211环氧树脂在不同激光脉冲数下的实际光斑直径与去除阈值通量
Table 2. Actual spot diameter and removal threshold flux of 4211 epoxy resin under different laser pulse numbers
脉冲数N 实际光斑直径 ds/μm 阈值通量 Fth/（J·cm−2） 1 19.16±0.36 0.44±0.04 3 18.17±0.46 0.31±0.02 6 19.95±0.41 0.28±0.02 10 22.10±0.54 0.25±0.02 20 23.18±0.77 0.19±0.02 50 24.22±0.72 0.15±0.01 100 26.50±0.86 0.14±0.01 300 26.69±0.98 0.09±0.01
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表 3 Kevlar 49芳纶纤维在不同激光脉冲数下的实际光斑直径与去除阈值通量
Table 3. Actual spot diameter and removal threshold flux of Kevlar 49 aramid fiber under different laser pulse numbers
N ds/μm Fth/（J·cm−2） 3 22.89±0.81 0.17±0.04 5 24.23±1.06 0.15±0.05 10 24.34±1.22 0.13±0.04 15 25.43±1.14 0.12±0.03 25 26.41±1.05 0.12±0.02 50 25.92±1.30 0.11±0.03 100 27.32±1.22 0.10±0.02 250 27.57±1.47 0.06±0.01 300 27.68±1.52 0.06±0.01
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表 4 AFRP复合材料参数
Table 4. AFRP composite material parameters
厚度/mm 纤维质
量分数/%密度/
（kg·m−3）热导率/
(W·(m·K)−1)拉伸
强度/MPa拉伸
模量/GPa1 65 1.3 <1 1800 100
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表 5 Kevlar49/4211芳纶碳纤维在不同激光脉冲数下的实际光斑直径与去除阈值通量
Table 5. Actual spot diameter and removal threshold flux of Kevlar49/4211 aramid carbon fiber under different laser pulse numbers
N ds/μm Fth/（J·cm−2） 3 19.56±1.75 0.29±0.04 5 17.63±1.60 0.27±0.04 10 20.01±2.41 0.22±0.03 15 20.62±1.77 0.19±0.03 25 21.20±2.42 0.16±0.02 50 23.75±4.63 0.14±0.02 100 25.55±6.01 0.12±0.02 250 24.73±5.29 0.09±0.02 500 25.61±6.67 0.07±0.01
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