Lasers are particularly useful for the precise machining of ceramics by virtue of their low force signature and cost effectiveness relative to traditional methods. However, the full potential of lasers has yet to be realized because of the fracture problems inherent to the brittle nature of ceramics and the associated higher manufacturing and environmental costs. One of the more vexing problems currently faced when machining unsupported ceramics is the premature fractures that occur as the cut is almost completed and the remaining section is unable to support the component weight. While simple supports on the underside of the component can offset this problem, they are not always practical and/or economical in a manufacturing setting. As a result, premature fractures, separation burrs, and chips can occur along with micro-cracks. Unfortunately, such damage can often prove to be costly since the entire component may have to be scrapped. To help avoid this problem, research funded by the National Science Foundation is investigating new laser-machining methods that hold the promise of improving quality and throughput by delaying fractures and potentially healing micro-crack damage.

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