Experimental investigation on: Laser shock micro-forming process using the mask and flexible pad

• The mask and flexible laser shock forming process were investigated.
• The mask and the laser beam were employed as the variable convex mold.
• The plasticine was used as the flexible support.
• The pulse energy, grain size, and the number of the laser pulse were investigated.
• Surface quality and thickness distribution of the workpiece were analyzed.

A forming process called the mask and flexible pad laser shock forming was proposed to fabricate the micro-features on the copper foil. In this process, the mask and laser beam were used as rigid punches. Shock waves induced by plasma were used as the source of loading and plasticine was used as a flexible pad. This was a micro scale and high strain rate forming process and the traditional forming method with micro-mold was changed. In the experiment, surface morphology of formed parts was represented and it was found that the mask played a significant role in the forming process. In order to understand the forming process in the experiment, process parameters, including laser pulse energy, numbers of laser pulse and grain size, were analyzed. The experimental results showed that different parameters had different effects on formed parts. The surface quality and the thickness distribution of formed parts were investigated. It was found that formed parts could keep good surface quality after laser shocking and the reasons were explored. The thickness distribution was measured and the thickness thinning rate was calculated. There was no local tightening or rupture in the forming area. In this paper, the micro-features could be obtained on metallic foils and the method of mold-free was proved to be feasible.