Experimental study of laser induced decomposition based processing of a brittle plastic, CR-39 (allyl diglycol carbonate)

A cw CO2 laser, coupled with an astigmatism free beam focussing mirrors arrangement is used for processing a brittle plastic, CR-39 without producing cracks, vents or chips. The processing is based on the formation of volatile products of laser-induced decomposition in the plastic. Threshold fluence for the decomposition (found to be independent of the power density and beam residence time) in CR-39 at λ=10.6μm is determined to be 25 J cm-2 and the decomposition threshold power density for cw irradiation 2.1±0.5 W cm-2. The depth and width of the tapered laser processed region are observed to increase with power density and beam residence time. The widths attain a steady state value of 1 mm at beam residence time above 65 ms, for a fixed power density (2.5×104 W cm-2) and sheet thickness (250 μm). Taper angle of the edges decreases with increasing power density and/or beam residence time. The heat affected zone (measured in crossed polarisers) around the processed region is found to extend with increasing beam residence time but remains unaffected on changing power density. The results are discussed in terms of the optical and thermophysical properties of CR-39 and the parameters of the interacting laser beam