Long GHz-Burst Laser Surface Polishing of AlSl 316L Stainless Steel Parts Manufactured by Short GHz-Burst Laser Ablation

GHz-burst laser polishing is as a promising technique for improving the surface quality of metallic materials, offering key advantages over conventional methods. In this study, two distinct approaches are investigated: a single-step polishing process, and a double-step process consisting of an initial laser milling step followed by a finishing/polishing pass. This distinction is critical in evaluating the performance of GHz-burst regimes under different surface conditions and roughness levels. Initial proof-of-concept trials confirm that GHz-burst irradiation can significantly reduce the surface roughness with minimal thermal damage, provided that process parameters are carefully optimized. Further analysis of spot-to-spot overlap reveals that the deposited energy density plays a crucial role in achieving uniform surface quality without inducing surface defects. The number of passes is also studied, showing that while multiple passes can improve surface finish, the benefit strongly depends on the initial roughness state of the substrate. Scalability is demonstrated by increasing both the repetition rate and scan speed proportionally while maintaining processing quality across larger areas. These results support the viability of GHz-burst laser polishing for high-throughput manufacturing. Applications in aerospace, biomedical implants, and precision optics highlight the technique’s potential for industrial adoption in demanding surface finishing contexts.