Numerical modeling to predict threshold fluence for material ejection in Laser-Induced forward transfer of metals

Abstract

Laser-induced forward transfer (LIFT) uses a pulsed laser beam to propel material from a donor (containing a glass coated with a thin material film) onto a receiving substrate, resulting in pixellated material deposition. The deposition characteristics depend on the material ejection modes that vary with film thickness and laser parameters. This study develops a computational model based on the
finite volume method for LIFT of gold films using nanosecond pulses, which captures two different ejection modes for droplet deposition —cap ejection and jet ejection. The model computes the temperature distribution and predicts potential ejection regimes for different film thicknesses, providing an understanding of the material removal process. Cap ejection occurs at lower laser fluences when
the entire film thickness in the irradiated zone is in the molten phase. In comparison, jet ejection occurs at higher laser fluences caused by vapor pocket formation at the glass-film interface. The model predicts threshold fluences with greater than 90% accuracy for film thickness less than 583 nm. However, for the film thickness of more than 583 nm, the simulations underpredict the threshold fluence, suggesting that laser absorption by the film decreases due to vapor formation at the glass-film interface. Besides, it is observed that higher fluences can cause melting and vaporization of the glass at the interface leading to possible contamination of the deposited material. The proposed model can be used to choose the operating window for laser parameters for droplet deposition in LIFT, which otherwise is challenging using experiments.