Joining metal and glass for certain manufacturing applications is not an easy feat, as the adhesives used can creep and outgas, leading to reduced product lifetime. A more efficient process for marrying these two seemingly incompatible materials has been pioneered at Herriot-Watt University, U.K.

The new welding method merges metal and glass by use of picosecond-duration laser pulses. Joining is accomplished by directing the laser at the interface between the two materials held in close contact, creating a microplasma in the middle of a highly confined melt region. Tests achieved megawatt peak power in an area measuring a few microns across and demonstrated the joining of borosilicate glass, quartz and sapphire to aluminum, titanium and stainless steel.

The laser-activated welds were also shown to remain intact when subjected to a temperature range of -50° C to 90° C.

The team is now working with specialists to commercialize the welding process, which could benefit manufacturing in the aerospace, defense, optical technology and healthcare sectors.