High-power pulsed-laser ablation of aluminum alloy: Simulation model and experimental validation

To address the critical influence of pulse shape on the laser ablation of metallic materials, this study proposes a comprehensive methodology that integrates finite‑element numerical simulations with experimental validation. Based on the spatiotemporal energy‑distribution characteristics of Gaussian and super‑Gaussian pulses, the temperature evolution, plasma electron density, and ablation efficiency of 6061 aluminum alloy were systematically analyzed under various single‑pulse energies and spot radii. Comparison between experimental measurements and numerical predictions enables the construction of an energy‑coupling model for laser ablation and establishes a theoretical framework describing how pulse shape governs the material’s thermal response and plasma dynamics. The performance of the experimental laser was benchmarked against that of a commercial laser. The results show that the maximum difference in dispersion coefficients between the two lasers is only 0.19%, and the largest discrepancy in average perforation time between the Gaussian and super‑Gaussian pulses is approximately 6 s. Owing to its more uniform energy distribution, the super‑Gaussian pulse exhibits 3–18% higher energy‑coupling efficiency and material‑removal efficiency under identical energy input. Therefore, controlling the pulse shape can significantly enhance the stability and efficiency of laser ablation, satisfy the requirements of high‑precision material processing regarding energy‑distribution uniformity and ablation consistency, and provide a theoretical foundation for applying pulse‑shaping techniques in high‑efficiency laser manufacturing.