Critical pulse in multi-shot femtosecond laser ablation on metallic surfaces

Thermal effect remains a thorny issue for femtosecond-laser surface engineering and nanostructuring on metallic targets with high pulse energies or high repetition rates, which needs to be paid adequate attentions. Herein, we have experimentally investigated the heat diffusion and accumulations during single-shot and multi-shot femtosecond laser ablation on metallic surfaces. We have for the first time observed a novel phenomenon that the thermal effect was intensified abruptly when the laser-pulse number goes over a threshold (approximately between 10 and 20 for aluminum alloy with laser fluence of 6 J cm-2), accompanied with a dramatic reduction of ablated depth and complicated plasma dynamics. Based on both optical and thermodynamic analysis, we introduced a defocusing-dominated plasma-assistant model for this abnormal thermal effect. This work explored the critical experimental parameters for femtosecond-laser surface modification and processing in micro-scale engineering applications.