Suppression of microcracks in femtosecond laser grooving of aluminum using a flame environment

Femtosecond laser machining of aluminum often suffers from microcrack formation and edge irregularities, affecting processing quality. This study explores the impact of a flame environment on groove characteristics. Results show that in ambient air, high-energy laser pulses induce microcracks, especially at high scanning speeds, while the flame environment suppresses microcracks and improves edge uniformity. The flame preheats the material, reduces thermal shock, and enhances material removal, leading to deeper and more consistent grooves. These findings provide insights for optimizing laser processing parameters to improve machining stability and surface quality.