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. The low-stress Solderjet Bumping technique was employed to assemble the optical components of an increased-robustness laser spark-plug ignition device using the low melting alloys 96.5Sn3Ag0.5Cu and 80Au20Sn. A finite-element-method analysis, optical simulations, and a soldering parametrization test were performed to prove that different optical materials (sapphire, ECO-550, D-ZLaF52LA, TAC4, and N-SF11 glasses) could be fastened to the stainless steel body. The assembled spark-plug device featured a passively Q-switched Nd  :  YAG/Cr4  +    :  YAG composite ceramic medium and delivered laser pulses with energy variable between 2.40 and 4.70 mJ, with 0.8 ns duration, suitable for inducing air breakdown phenomenon and engine combustion.

Assembly process and optical performances for a golden laser spark-plug device