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arXiv · 2608.28423

High-performance silicon-metal laser welding resisting extreme conditions

Jiawei Yin·Markus Blothe·Hagen P. Kohl·Christina Schütze·Stefan Nolte·Maxime Chambonneau
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Abstract

Reliable material joining is essential for countless industrial applications. While femtosecond laser welding provides a route beyond conventional bonding methods, demonstrations of silicon-metal joints are rare due to nonlinear propagation effects and have so far been limited to shear joining strengths of a few MPa. Here, we demonstrate high-strength silicon-Kovar laser welding using sub-nanosecond pulses. By optimizing the focal position, the welding pattern, the laser polarization, and the metal roughness, remarkable shear joining strengths up to 15.8 MPa are achieved. The silicon-metal joints withstand temperatures of up to 500 °C and are hermetically sealed. Together with the remarkable strength values, the resistance to harsh environments underpins the applicability of silicon-metal welding in various fields including aerospace, nuclear science, and metallurgy.

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Jiawei Yin, Markus Blothe, Hagen P. Kohl, Christina Schütze, Stefan Nolte, Maxime Chambonneau. 2026-08-28. High-performance silicon-metal laser welding resisting extreme conditions. https://arxiv.org/abs/2608.28423

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