Monte Carlo Simulation and Experimental Investigation of Back Strike Protection in Laser Drilling

Qingyang Zeng; Bin Wang; Wenwu Zhang

doi:10.3788/CJL231321

Chinese Journal of Lasers, Volume. 51, Issue 16, 1602409(2024)

Monte Carlo Simulation and Experimental Investigation of Back Strike Protection in Laser Drilling

Qingyang Zeng^1,2,3, Bin Wang^1,2, and Wenwu Zhang^1,2、*

Author Affiliations

¹Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo 315201, Zhejiang , China

²Zhejiang Key Laboratory of Aero Engine Extreme Manufacturing Technology, Ningbo 315201, Zhejiang , China

³University of Chinese Academy of Sciences, Beijing 100049, China

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Abstract Get PDF(in Chinese)

Figures & Tables(16)

Fig. 1. Schematics of the computational and random value domains (figures have been scaled to be easier to read). (a) p<t; (b) p≥t

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Fig. 2. Variation of Monte Carlo simulation results with amount of data. (a1)(a2) Diameter of protective material particles p=0.05 mm; (b1)(b2) p=0.3 mm; (c1)(c2) p=0.7 mm

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Fig. 3. Violin diagram of Monte Carlo simulation results for blocking rate

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Fig. 4. Schematics of the laser processing system and the back strike protection. (a) Laser processing system; (b) without protective material; (c) with protective material

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Fig. 5. Schematics of test piece and measuring result of typical back strike pit (400×, standard order No.5). (a) Schematic of test piece;

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Fig. 6. Main effects plots for depth of back strike pit

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Fig. 7. Schematic of the breakthrough timing experiment

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Fig. 8. Processing of calculating breakthrough time from the video frames. (a) SiC; (b) graphite; (c) ZrO₂; (d) Al alloy front wall

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Fig. 9. Breakthrough time comparison of different materials

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Table 1. Algorithm process of Monte Carlo simulation

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Table 1. Algorithm process of Monte Carlo simulation

Monte Carlo simulation： overlap area between laser processing area and protective particles

input： Diameter of protective material particles P =［p₁， p₂， p₃， ···， p_i， ···， p_n］； Diameter of laser drilling t； Groups of particle diameter n； Maximum of Monte Carlo simulations for each set of particle diameters N_max

output： overlap area data matrix O

1： Initialize the overlap area data matrix O in n×N_max；

2： fori=1， 2， ···， n do

3： ifP（i）<t do

4： The calculation area， particle arrangement， and drop range are constructed according to Fig. 1（a）；

5： elsedo

6： The calculation area， particle arrangement， and drop range are constructed according to Fig. 1（b）；

7： end if

8： Generate N_max×2 randomized drop matrices within the drop range ［X，Y］=［x₁， y₁； x₂， y₂； ···； x_k， y_k； ···； x_N_max， y_N_max］；

9： Initialize loop variable k=1；

10： whilek≤N_max do

11： Calculate the overlap area o_ik between the laser processing region centered at ［X， Y］（k，：） and the shape of particles；

12： O（i， k）=o_ik；

13： k=k+1；

14： end while

15： end for

16： return O

Table 2. Parameters of the laser source and optical component
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Table 2. Parameters of the laser source and optical component
Parameter Value
Wavelength /nm 532.0
Average power /W ≤32.9
Pulse repetition rate /kHz 10.0‒50.0
Pulse width /ns ≥23.2
Focus length /mm 163.0
Spot size /μm 30.65

Table 3. Physical and chemical properties of filling materials

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Table 3. Physical and chemical properties of filling materials

Material	Physical form	Molar mass /（g/mol）	Density /（g/m³）	Melting point /℃	Boiling point /℃
Graphite （C）	Black irregular crystals	12.011	2.20	4489 （10.4 MPa）	3825 （sublimation point）
Zirconium oxide （ZrO₂）	White spherical powder	123.223	5.68	2710	4300
Silicon carbide （SiC）	Green-black irregular crystals	40.097	3.16	2830

Table 4. Chemical composition of 6061 aluminum alloy and GH3536 nickel-based superalloy

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Table 4. Chemical composition of 6061 aluminum alloy and GH3536 nickel-based superalloy

Material

Mass fraction /%

Other elements

Bal.

6061

0.4‒0.8

0.7

0.15‒0.40

0.8‒1.2

0.04‒0.35

Ti： 0.15； Mn： 0.15；

Zn： 0.25

GH3536

0.33

18.76

0.02

1.32

20.94

6.64

Al： 0.40； W： 0.86；

Mn： 0.61； C： 0.08

Table 5. Factor level setting table
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Table 5. Factor level setting table
Level A （material， text factor） B （binder， text factor） C （pulse repetition rate /kHz） D （processing time /s）
-1 ZrO₂ （spherical） Not added 10 2
0 30 6
1 SiC （irregular） Added 50 10

Table 6. Screening DOE design and experimental results

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Table 6. Screening DOE design and experimental results

Standard order	A （material， text factor）	B （binder， text factor）	C （pulse repetition rate /kHz）	D （processing time /s）	Response （depth of back strike pit /μm）
1	SiC	Added	50	10	207.46
2	ZrO₂	Not added	10	2	0
3	ZrO₂	Not added	50	2	298.61
4	SiC	Added	10	10	0
5	ZrO₂	Added	30	10	427.93
6	SiC	Not added	30	2	0
7	ZrO₂	Not added	50	6	300.10
8	SiC	Added	10	6	0
9	ZrO₂	Not added	10	10	331.38
10	SiC	Added	50	2	0
11	ZrO₂	Added	10	2	0
12	SiC	Not added	50	10	478.98
13	SiC	Not added	30	6	270.37
14	ZrO₂	Added	30	6	421.99

Table 7. ANOVA and significance test for the model of depth of back strike pit

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Table 7. ANOVA and significance test for the model of depth of back strike pit

Source	Degrees of freedom	Adjusted mean squares	F-value	P-value	Significance level
Model	7	61556	12.35	0.0035	**
Linear	4	89245	17.91	0.0017	**
A （material）	1	101347	20.34	0.0041	**
B （binder）	1	17299	3.47	0.1117
C （pulse repetition rate）	1	104437	20.96	0.0038	**
D （processing time）	1	185584	37.24	0.0009	**
Square	1	65070	13.06	0.0112	*
C×C	1	65070	13.06	0.0112	*
2-way interactions	2	16921	3.40	0.1032
A×D	1	12671	2.54	0.1619
B×D	1	31221	6.27	0.0463	*
Error	6	4983
Total	13

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Qingyang Zeng, Bin Wang, Wenwu Zhang. Monte Carlo Simulation and Experimental Investigation of Back Strike Protection in Laser Drilling[J]. Chinese Journal of Lasers, 2024, 51(16): 1602409

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