Finite Element Analysis of Thermal–Mechanical Coupling and Process Parameter Optimization in Laser Etching of Al–Tedlar–Kevlar Composite Films

Laser processing of heterogeneous composites requires a clear understanding of coupled thermal and mechanical responses to ensure structural integrity and patterning precision. In this study, a thermal-mechanical coupling model based on the finite element method was developed to investigate laser-material interactions in Al-Tedlar-Kevlar composite films. The effects of key parameters-including pulse energy, spot size, pulse duration, and repetition frequency-on the evolution of temperature and stress fields were systematically examined. The simulations reveal that pulse energy leads to a linear rise in peak temperature, while pulse duration exerts a nonlinear influence on energy density and thermal uniformity. Increasing repetition frequency promotes thermal accumulation, enlarging the heat-affected zone. Coupled analyses further indicate significant stress concentrations at material interfaces, which may trigger delamination and compromise film reliability. Through comprehensive parameter evaluation, the optimal processing conditions were identified as 0.5 mJ pulse energy, 20 kHz repetition rate, 45 μm spot diameter, and 120 ns pulse duration. These findings clarify the governing mechanisms of thermal-mechanical interactions in multilayer composites and provide theoretical guidance for optimizing laser micropatterning processes while enhancing interfacial stability and manufacturing quality.