Predictive ultrafast-laser-enabled microwelding using dynamic pulse propagation modelling

We present a dynamic pulse propagation modelling and experiments for femtosecond laser bonding of glass to glass/metal. The modelling provides quantitative estimates of the heat affected zone and weld geometry, incorporating the nonlinear electron dynamics along with temperature-dependent thermal properties. The model numerically determines the desired relative position between the geometrical focus of a femtosecond-laser-pulse and the interface of the two substrates to be welded, for the first time to our knowledge. The welding results of two similar and/or dissimilar materials using the model-predicted weld geometry and offset distance will be presented. This research was supported by NASA SBIR contract 80NSSC20C0432.