Hole Morphology and Keyhole Evolution during Single Pulse Laser Drilling on Polyether-Ether-Ketone (PEEK)

Polyether-ether-ketone (PEEK), with its superior mechanical, chemical, and thermal properties, as well as high biocompatibility, has been used in aerospace, electronics, and biomedical applications. In this paper, a large number of experiments of single-pulse laser drilling on PEEK were performed to analyze the hole morphology and keyhole evolution, which were characterized by an optical microscope, charge-coupled device (CCD), and high-speed camera. A novel method is proposed to observe and measure the dimension of the processed hole rapidly right after laser drilling for special polymer materials with wear-resistance and non-conductivity. Morphological characteristics of holes are presented to illustrate the effect of pulse width and peak power on hole depth, hole diameter, and aspect-ratio. The obtained maximum drilling depth was 7.06 mm, and the maximum aspect-ratio was 23. In situ observations of the dynamic process of laser drilling, including the keyhole evolution together with ejection and vaporization behavior, were also carried out. The keyhole evolution process can be divided into three stages: rapid increment stage (0–2 ms) at a rate of 2.1 m/s, slow increment stage (2–4 ms) at a rate of 0.3 m/s, and stable stage (>4 ms). Moreover, the variation of dimensionless laser power density with the increase in pulse width was calculated. The calculated maximum drilling depth based on energy balance was compared with the experimental depth. It is proven that the laser–PEEK interaction is mainly influenced by a photothermal effect. Ejection is the dominant material-removal mechanism and contributes to over 60% of the depth increment during the rapid increment stage, while vaporization is dominant and contributes to about 80% of the depth increment during the slow increment stage. The results reveal the material removal mechanism for single-pulse laser drilling on PEEK, which is helpful to understand the dynamic process of keyhole evolution. This not only provides a processing window for future laser drilling of PEEK but also gives a guide for the manufacturing of other polymers.