Defect Free and Robust Microstructuring Using Femtosecond Axicon-lens-focused Beam (FAB) with Application Focus in Thin Film Solar Cell Manufacturing

该研究项目的目标是研究飞秒近无衍射激光束与太阳能薄膜等先进材料之间的物理相互作用，并揭示此类材料微结构化的烧蚀机制。研究方法将包括实验研究和数值模拟。将进行一项全面的实验研究，以评估激光束成形和操作参数对工艺鲁棒性、效率和切割质量的影响。一个激光烧蚀模型将被开发，以阐明基本的烧蚀机制，并优化工艺条件。这项工作的成功完成将在飞秒激光与先进材料相互作用领域产生新的基础知识。新的知识将作为科学基础，在此基础上可以开发新的飞秒激光微加工工艺。所提出的微结构化过程中有许多领域的应用，包括划线的太阳能电池，微机电系统和发光二极管，微钻孔在汽车和航空航天工业，表面纹理的摩擦组件等，在太阳能行业，例如，一个显着增加薄膜太阳能电池板的转换效率将实现使用所提出的划线过程。再加上通过卷对卷大规模生产显着降低成本的潜力，该项目将有助于国家？我们的未来是没有空气污染、危险废物和全球变暖的清洁能源。除了对制造业的影响外，还将开发引人入胜的教育材料和活动，以培训多样化的本科生和研究生群体，并教育K-12学生和公众。

The objective of this research project is to study the physical interactions between a femtosecond near-nondiffracting laser beam and advanced materials such as solar thin films and reveal the ablation mechanisms in microstructuring of such materials. Research approaches will include both experimental investigation and numerical modeling. A comprehensive experimental study will be conducted to assess the effects of laser beam shaping and operating parameters on process robustness, efficiency and cut quality. A laser ablation model will be developed to elucidate the basic ablation mechanisms and to optimize process conditions. The successful completion of this work will generate new fundamental knowledge in the area of femtosecond laser interaction with advanced materials. The new knowledge will serve as the scientific foundation based on which new femtosecond laser micromachining processes can be developed. The proposed microstructuring process has applications in numerous areas including scribing of solar cells, micromachining of microelectromechanical systems and light-emitting diodes, microdrilling in automotive and aerospace industry, surface texturing for tribological components, etc. In the solar industry, for example, a significant increase in conversion efficiency for thin film solar panels will be achieved using the proposed scribing process. Together with the potential of significantly reducing cost through roll-to-roll mass production this project will contribute to the nation?s clean energy future free of air pollution, hazardous waste, and global warming. Besides impacts on manufacturing industry, fascinating education materials and activities will be developed to train a diverse group of undergraduate and graduate students and to educate K-12 students and the general public.