Direct Glass-to-Metal Welding by Femtosecond Laser Pulse Bursts: II, Enhancing the Weld Between Glass and Polished Metal Surfaces

We present a comprehensive study on the femtosecond laser direct welding of glass and metal, focusing on optimizing processing parameters and understanding the influence of material properties and beam shaping on welding quality. Using microscopy, we identified optimal pulse energy, focal position, and line-spacing for achieving high-quality welds. We further investigated the effects of laser beam shaping and material property differences in various glass-to-metal pairs, including borosilicate, fused silica, and Zerodur glasses welded with mirror-polished metals such as Cu, Mo, Al, Ti, and AISI316 steel. Our results show that Ti and AISI316 steel exhibit the lowest adhesion to borosilicate and fused silica glasses, while Zerodur glass achieves good adhesion with all tested metals. To understand the weldability differences among material pairs, we employed a time-dependent finite-element method to analyze the laser heating-induced thermal stress. Our findings indicate that the welding quality is significantly influenced by the choice of materials and beam shaping, with the vortex beam showing potential for improved welding outcomes. This study provides valuable insights for optimizing glass-to-metal welding processes for various industrial applications.