As an advanced non-contact processing technology, laser processing technology has shown prominent technical advantages and broad application prospects in high-efficiency oil and gas development. It has become an important technical approach for hard rock breaking in deep and ultradeep wells, precision perforation, and microstructural characterization of cores. Currently, the three most widely used laser types in oil and gas engineering are continuous-wave fiber lasers, nanosecond pulsed lasers, and femtosecond pulsed lasers; however, a systematic understanding of the interaction mechanisms between these lasers and sandstone remains lacking. Existing experimental studies also exhibit prominent limitations, including fragmented experimental systems, ambiguous multifactor coupling correlations, and insufficient integration between mechanism investigations and engineering applications. To address these shortcomings, this study designs a comprehensive experiment of laser processing of sandstone for oil and gas development and establishes a full-process experimental system integrating parameter optimization and mechanism analysis.

Systematic experimental investigations were conducted on sandstone laser processing using the three typical laser types mentioned above. A progressive experimental system was established, including comparative tests of their basic characteristics, single-factor controlled experiments, and multifactor orthogonal experiments. Standardized sandstone sample preparation was performed to minimize the influence of sample heterogeneity on experimental results. The core process parameters of the three laser types were optimized and calibrated to establish baseline conditions for subsequent experiments. Single-factor experiments were conducted using a controlled variable method to quantify the influence of key parameters on sandstone processing performance, and thermal effect simulations were completed via ANSYS software to verify the experimental results. Based on the single-factor experiment results, an L9 orthogonal array with three factors and three levels was designed for representative oil and gas development scenarios. Range analysis was used to determine the relative influence of different process parameters and identify the primary controlling factors. Integrated macro- and microscale characterization was performed with an ultra-depth-of-field 3D optical microscope and scanning electron microscope to elucidate the laser–sandstone interaction mechanisms under thermal and nonthermal processing modes. Rock breaking efficiency, hole morphology, processing accuracy, and heat-affected zone width were selected as core evaluation indicators to verify the engineering feasibility of the optimized process.

The experimental results revealed four key findings. First, the comprehensive experimental system effectively quantified the fundamental processing characteristics of sandstone processing under the three laser types and clarified their distinct interaction mechanisms. Continuous-wave fiber lasers and nanosecond pulsed lasers were primarily governed by thermal effects, while femtosecond pulsed lasers enabled nonthermal processing with negligible heat-affected zones. The applicable ranges of different laser technologies for oil and gas development scenarios were therefore established. Second, range analysis of the orthogonal experiment identified the dominant control factors for different processes. Laser power was found to be the key factor controlling deep well rock breaking using continuous-wave fiber lasers, with a range value of 0.12. Processing duration was the primary parameter affecting reservoir perforation using nanosecond lasers, with a range value of 3.02. Objective lens magnification was the dominant factor influencing microstructure modification using femtosecond lasers, with a range value of 32.51. Third, scenario-based verification using optimized process parameters showed that the optimized continuous-wave fiber laser process improved rock-breaking efficiency by 42% compared with the baseline parameters. The optimized nanosecond laser process increased the regularity of hole morphology during reservoir perforation by 35%, while the femtosecond laser achieved micron-level precision without thermal damage, satisfying the engineering requirements of different oil and gas development scenarios. Fourth, repeatability tests showed that the relative standard deviations of key indicators, such as processing aperture and rock breaking depth, were below 5% under the optimal conditions for all three laser types, confirming the stability and reproducibility of the proposed experimental approach.

By integrating statistical analysis and multidimensional characterization techniques, this study establishes a complete closed-loop experimental system encompassing parameter optimization, mechanism analysis, and engineering application. The developed methodology achieves the expected research objectives by clarifying the interaction mechanisms between different laser types and sandstone, thereby providing systematic experimental guidance and a reliable data foundation for the mechanism investigation, process optimization, and engineering application of laser processing technology in oil and gas development.

Intelligent Sensing Engineering is an emerging discipline that responds to the ongoing technological revolution and industrial transformation. Established with a focus on meeting the national demands in emerging industries, this interdisciplinary field is a significant research topic for the development of intelligent sensing education. The design of sensor courses holds a key position in the curriculum, serving as a vital link between foundational and advanced concepts. The traditional sensor course at our institution primarily addresses the design and development of analog sensor interface circuits for Pt100 resistance temperature detectors. However, the fixed experimental procedures and a singular approach have impacted student enthusiasm in this regard. In contrast, flexible sensors, as a novel technology with broad innovation potential, have become a driving force in the era of intelligent sensing. Hence, incorporating the design of sensors in the curriculum has become imperative to familiarize students with the structures and system design concepts of new types of flexible sensors, such as graphene-based sensors. To cultivate students’ abilities for independent learning, practical application, innovation, and solving complex engineering problems, a comprehensive course was designed.

This course integrates the production of flexible sensors, the construction of measurement circuits, data processing methods, and system calibration. Through this course, students can explore new application areas, design innovative intelligent sensing devices, and develop creative thinking and problem-solving skills. The goal is to enhance students’ comprehensive skills and knowledge across multiple disciplines, covering the design of sensitive elements, conversion components, and conversion circuitry. The course also explores the manufacturing of flexible sensors using advanced materials, providing an in-depth understanding of the working principles and current production philosophies of advanced flexible sensors. By integrating knowledge from electronic engineering, materials science, and mechanical engineering, the course aims to foster students’ holistic competence. Practical exercises allow students to foster hands-on skills, independent critical thinking, and problem-solving abilities, thus cultivating talents with enhanced innovation, engineering practice, and research capabilities.

Compared to graphene, graphite, owing to its electrical properties being less influenced by various factors, is less common in the production of standard sensors. However, its layered structure and ease of cutting and bending make it convenient for students to personalize their creations within the sensor system. In contrast to mature standardized sensors, the performance of graphite flexible sensors is influenced by additional factors, such as environmental temperature, graphite purity, cross-sectional area, and length. This complexity provides students with opportunities to develop problem-solving skills, exercise variable control, and enhance data processing capabilities, merging theoretical sensor knowledge with practical applications. The designed course on graphite flexible pressure sensors effectively improves the teaching methods in the new field of Intelligent Sensing Engineering. [Conclusion] This innovative teaching approach not only increases the student’s interest in the course but also develops their ability to think innovatively using acquired knowledge. Moreover, the design of this course effectively hones students’ practical innovation skills, making them more competitive in the job market. Furthermore, it helps meet the growing demand for talent in the field of Intelligent Sensing Engineering. In addition, being abreast with the cutting-edge technologies in the field, students gain detailed insights into the latest research findings, thus laying a solid foundation for subsequent research work for both senior undergraduate and graduate students.