Degradation mechanisms in laser-based manufacturing: A review of unresolved challenges of aging surfaces in electronics production

Laser surface modification, including ablation cleaning, deterministic texturing, and formation of Laser-Induced Periodic Surface Structures (LIPSS), is increasingly adopted in electronics production for oxide removal, wettability enhancement, and joining preparation on Cu, Al, and Fe-alloy substrates. While the immediate post-process benefits are well established, the temporal stability of these laser-induced functional properties under realistic storage and service conditions remain insufficiently understood. This systematic literature review, based on 109 articles identified through Scopus, Web of Science, IEEE Xplore, and Google Scholar, analyzes the current knowledge on degradation mechanisms of laser-modified metallic surfaces with focus on electronics production. The dominant degradation pathway, a spontaneous wettability transition from superhydrophilic to hydrophobic driven by progressive oxidation and ambient organic contamination, is consistently reported but studied almost exclusively over periods below 30 days and under uncontrolled laboratory conditions. Critical knowledge gaps are identified regarding long-term functional property evolution (solderability, electrical contact resistance, bond strength), degradation under thermomechanical cycling, LIPSS nanostructural stability, and the absence of standardized aging protocols. Research directions are proposed to enable shelf-life specifications and process window definitions for industrial adoption.