{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,9,14]],"date-time":"2026-09-14T09:07:00Z","timestamp":1789376820207,"version":"build-2803163510"},"reference-count":48,"publisher":"MDPI AG","issue":"18","license":[{"start":{"date-parts":[[2026,9,14]],"date-time":"2026-09-14T00:00:00Z","timestamp":1789344000000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"DOI":"10.13039\/501100012166","name":"National Key R&D Program of China","doi-asserted-by":"publisher","award":["2023YFB4605500"],"award-info":[{"award-number":["2023YFB4605500"]}],"id":[{"id":"10.13039\/501100012166","id-type":"DOI","asserted-by":"publisher"}]},{"name":"Key Program for Basic Research","award":["JCKY2024210A001"],"award-info":[{"award-number":["JCKY2024210A001"]}]},{"name":"Science and Technology Innovation Program of Hunan Province","award":["2026RC3008"],"award-info":[{"award-number":["2026RC3008"]}]},{"DOI":"10.13039\/501100004735","name":"Natural Science Foundation of Hunan Province","doi-asserted-by":"publisher","award":["2026JJ50177"],"award-info":[{"award-number":["2026JJ50177"]}],"id":[{"id":"10.13039\/501100004735","id-type":"DOI","asserted-by":"publisher"}]},{"name":"State Key Laboratory of Ultrafast Optical Science and Technology","award":["2025SKL-uFAST-KF22"],"award-info":[{"award-number":["2025SKL-uFAST-KF22"]}]},{"name":"State Key Laboratory of Precision Manufacturing for Extreme Service Performance","award":["ZZYJKT2026-06"],"award-info":[{"award-number":["ZZYJKT2026-06"]}]},{"name":"State Key Laboratory of Precision Manufacturing for Extreme Service Performance","award":["KFKT 2024-16"],"award-info":[{"award-number":["KFKT 2024-16"]}]},{"name":"State Key Laboratory of Precision Manufacturing for Extreme Service Performance College of Mechanical and Electrical Engineering Central South University","award":["1053320251946"],"award-info":[{"award-number":["1053320251946"]}]},{"DOI":"10.13039\/501100001809","name":"National Natural Science Foundation of China","doi-asserted-by":"publisher","award":["52105498"],"award-info":[{"award-number":["52105498"]}],"id":[{"id":"10.13039\/501100001809","id-type":"DOI","asserted-by":"publisher"}]},{"award":["52105498"],"award-info":[{"award-number":["52105498"]}],"id":[{"id":"https:\/\/ror.org\/01h0zpd94","id-type":"ROR","asserted-by":"publisher"}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Nanomaterials"],"abstract":"<jats:p>Fused silica\u2013aluminum alloy dissimilar connections are in urgent demand in fields such as aerospace optoelectronic packaging, vacuum optical windows, and micro-electro-mechanical systems, yet the dramatic mismatch in thermal-expansion coefficient and thermophysical properties between the two materials has long been a bottleneck for reliable joining. Current ultrafast laser welding of such heterogeneous systems still suffers from prominent problems, including stringent optical contact requirements, high crack sensitivity on the fused silica side, and unclear coupling mechanism between clamping conditions and joint defects. This work systematically studies the joining process of femtosecond laser welding of fused silica and 6061 aluminum alloy dissimilar materials, focusing on the effects of scanning speed, pulse energy, scanning spacing, and fixture preload on the shear strength, microstructure, and elemental diffusion behavior of the joints. The results confirm that scanning speed and scanning spacing have a synergistic effect on heat input density; the magnitude of the fixture preload is a key factor determining the interfacial residual stress and crack sensitivity. By optimizing the scanning speed (6 mm\/s) and combining it with a low preload and 140 \u03bcm scanning spacing, a high-strength heterogeneous joint with uniform elemental transition and no macroscopic cracks can be obtained. This study provides a detailed process-optimization approach for high-quality laser welding of dissimilar brittle\/ductile materials.<\/jats:p>","DOI":"10.3390\/nano16181147","type":"journal-article","created":{"date-parts":[[2026,9,14]],"date-time":"2026-09-14T08:10:23Z","timestamp":1789373423000},"page":"1147","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":0,"title":["Process Parameter Optimization and Crack Formation Mechanism of Femtosecond Laser Welding of Fused Silica\/6061 Aluminum Alloy"],"prefix":"10.3390","volume":"16","author":[{"given":"Donghan","family":"Li","sequence":"first","affiliation":[{"name":"State Key Laboratory of Precision Manufacturing for Extreme Service Performance, College of Mechanical and Electrical Engineering, Central South University, Changsha 410083, China"}],"role":[{"vocabulary":"crossref","role":"author"},{"role":"data-curation","vocabulary":"credit"},{"role":"validation","vocabulary":"credit"},{"role":"writing-original-draft","vocabulary":"credit"},{"role":"methodology","vocabulary":"credit"}]},{"given":"Yinzhi","family":"Fu","sequence":"additional","affiliation":[{"name":"State Key Laboratory of Precision Manufacturing for Extreme Service Performance, College of Mechanical and Electrical Engineering, Central South University, Changsha 410083, China"}],"role":[{"vocabulary":"crossref","role":"author"},{"role":"formal-analysis","vocabulary":"credit"},{"role":"data-curation","vocabulary":"credit"}]},{"given":"Jinlin","family":"Luo","sequence":"additional","affiliation":[{"name":"State Key Laboratory of Precision Manufacturing for Extreme Service Performance, College of Mechanical and Electrical Engineering, Central South University, Changsha 410083, China"}],"role":[{"vocabulary":"crossref","role":"author"},{"role":"supervision","vocabulary":"credit"}]},{"given":"Wen","family":"Li","sequence":"additional","affiliation":[{"name":"State Key Laboratory of Precision Manufacturing for Extreme Service Performance, College of Mechanical and Electrical Engineering, Central South University, Changsha 410083, China"}],"role":[{"vocabulary":"crossref","role":"author"},{"role":"formal-analysis","vocabulary":"credit"},{"role":"data-curation","vocabulary":"credit"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-8861-9726","authenticated-orcid":false,"given":"Xianshi","family":"Jia","sequence":"additional","affiliation":[{"name":"State Key Laboratory of Precision Manufacturing for Extreme Service Performance, College of Mechanical and Electrical Engineering, Central South University, Changsha 410083, China"}],"role":[{"vocabulary":"crossref","role":"author"},{"role":"investigation","vocabulary":"credit"},{"role":"conceptualization","vocabulary":"credit"},{"role":"supervision","vocabulary":"credit"},{"role":"resources","vocabulary":"credit"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-1290-1450","authenticated-orcid":false,"given":"Kai","family":"Li","sequence":"additional","affiliation":[{"name":"State Key Laboratory of Precision Manufacturing for Extreme Service Performance, College of Mechanical and Electrical Engineering, Central South University, Changsha 410083, China"}],"role":[{"vocabulary":"crossref","role":"author"},{"role":"supervision","vocabulary":"credit"},{"role":"project-administration","vocabulary":"credit"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-3608-507X","authenticated-orcid":false,"given":"Lu","family":"Zhang","sequence":"additional","affiliation":[{"name":"State Key Laboratory of Precision Manufacturing for Extreme Service Performance, College of Mechanical and Electrical Engineering, Central South University, Changsha 410083, China"}],"role":[{"vocabulary":"crossref","role":"author"},{"role":"supervision","vocabulary":"credit"},{"role":"project-administration","vocabulary":"credit"}]},{"given":"Yang","family":"Xiang","sequence":"additional","affiliation":[{"name":"Wuhan Huaray Precision Laser Co., Ltd.\u2014Professional Manufacturer of High-End Lasers, Wuhan 430074, China"}],"role":[{"vocabulary":"crossref","role":"author"},{"role":"supervision","vocabulary":"credit"},{"role":"project-administration","vocabulary":"credit"}]},{"given":"Cong","family":"Wang","sequence":"additional","affiliation":[{"name":"State Key Laboratory of Precision Manufacturing for Extreme Service Performance, College of Mechanical and Electrical Engineering, Central South University, Changsha 410083, China"}],"role":[{"vocabulary":"crossref","role":"author"},{"role":"supervision","vocabulary":"credit"},{"role":"resources","vocabulary":"credit"},{"role":"funding-acquisition","vocabulary":"credit"},{"role":"project-administration","vocabulary":"credit"}]}],"member":"1968","published-online":{"date-parts":[[2026,9,14]]},"reference":[{"key":"ref_1","first-page":"46","article-title":"Ultrafast laser welding of transparent materials: From principles to applications","volume":"7","author":"Jia","year":"2025","journal-title":"Int. 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