Reviews on laser cutting technology for industrial applications

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Reviews on laser cutting technology
for industrial applications
T. Muangpool, S. Pullteap
T. Muangpool, S. Pullteap, "Reviews on laser cutting technology for industrial
applications," Proc. SPIE 10714, Third International Conference on Photonics
Solutions (ICPS2017), 107140Q (5 March 2018); doi: 10.1117/12.2300955
Event: Third International Conference on Photonic Solutions, 2017, Pattaya,
Thailand
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Reviews on Laser Cutting Technology for Industrial Applications
T. Muangpool and S. Pullteap*
Department of Mechanical, Faculty of Engineering and Industrial Technology,
Silpakorn University, Nakhon Pathom, 73000, Thailand
*Email: saroj@su.ac.th
ABSTRACT
In this paper, an overview of the laser technology applied for the industrial has been reviewed. In general, this
technology was used in several engineering applications such as industrial, medical, science, research sectors, etc.
Focusing on the laser technology in the industrial section, it was, normally, employed for many purposes i.e. target
marking, welding, drilling, and also cutting. Consequently, the laser cutting technology was, however, divided into three
classifications YAG, CO2, and fiber laser, respectively. Each laser types have different advantages and disadvantages
depending on the material type. The advantages by using laser cutting compared with the general cutting machines were
exploited in terms of narrow kerf, high cutting speed, low heat-affected zone (HAZ), improve efficiency of the cutting
process, high accuracy, etc. However, the main objectives from the technology used were increasing of the products and
also decreasing the production cost. In the opposite way, some disadvantages of the technology were summarized by
complexity to operate, high maintenance cost, and also high power consumption. In Thailand industry, there were many
factories used this technology as a cutting process. Unfortunately, only few researches were published. It might explains
that this technology were difficulty to develop, high investment, and also easy to import from aboard. For becoming to
the Thailand 4.0 community, the Thailand industry might awareness to reduce the importing machine and boosting some
policies to create novel innovative / know-how from the own country.
Keywords: Industrial lasers, laser cutting machine, laser technology, Thailand 4.0
1. INTRODUCTION
Laser technology or the other words called as “laser” is the purest light that scientists produce. The laser word is
a synonym of “light amplification by simulated emission radiation” [1-2]. It is increasing the amount of light waves by
stimulating the release of the light. Laser energy has many characteristics depending on the purpose of the design.
Currently, laser applications are widely applied in several fields such as medical, medicine, surgery, ophthalmologist and
dental, etc [3-4]. In addition, it’s also used for homeostatic hemorrhage and cancer treatment [4]. Some lasers typical are
employed in medical applications including to the carbon dioxide laser (CO2), argon laser (Ar), etc. According to the
telecommunications field, the laser is, normally used as a transmitter through the optical fibers to transmit the designed
signals into equipment, telephones and computer [5]. Some advantages of the laser usage in telecommunication are
presented in terms of no noise, and more stable for the communication. Laser diode is a type of the laser technology
which has, widely, been applied in the offices and residential homes, such as laser pointer, laser printer, remote control
television, audio, and video. In various exhibitions, the laser is operated for advertising, theater, concerts. Moreover it
has been used in the metrological measurement as a standard for conveying accuracy in the dimensional measurement
systems and calibration the instruments. In the industrial sector, the laser technology is, generally, used for drilling,
cutting and welding of various materials, which the penetration patterns are small and very sharp [6]. Therefore, it has
ability to work in the highest resolution. Focusing on the applications of the laser for industry, it has been applied into 3
main classifications; cutting, welding, and drilling respectively. For the first type, it is using for scratching or cutting the
material under the computer numerical control (CNC) [7]. However, it is also divided into two sub-main types, moving
parts and flying optics respectively. For the first part, it is a way to move the work piece onto the desired direction for
marking and cutting. This method has ability to mark or cut with high resolution materials. The latter part is,
consequently, an alignment of the laser to move in the right direction. It is usually used in the large work areas and high
power lasers. However, the advantages by using lasers marking and cutting are no accumulation of heat in the material
which the material does not twist after cutting, high accurate and precise, no interference signal, etc. The laser welding is
using the laser beam to melt the two materials into a homogeneous. Its advantages are exploited in terms of very small
Third International Conference on Photonics Solutions (ICPS2017), edited by Athikom Roeksabutr, Kyu Yoshimori,
Proc. of SPIE Vol. 10714, 107140Q · © 2018 SPIE · CCC code: 0277-786X/18/$18 · doi: 10.1117/12.2300955
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welding points, shallow and narrow welds [8]. For the drilling laser, it’s, widely, operated for drilling holes that are very
small or used in the high hardness materials such as ceramics, diamonds etc. [9].
In this paper, we describes about the usage of the laser cutting for the industry. Moreover, we are investigating the
characteristic of such laser, cutting capacity of each laser machine, and also type of laser cutting. Furthermore, we are
summarizing some advantages and disadvantages of such laser for applying in the industry, especially for Thailand
industry.
2. OVERVIEWS OF LASER CUTTING TECHNOLOGY
Most of the lasers used in the manufacturing industry are employed for cutting in common materials, such as steel,
aluminum, stainless, thermoplastics, and other work pieces [10]. Laser beam cutting (LBC) is a process of cutting by
heat, which melts the material and becomes vaporized by the laser heat; the process uses gas to remove the molten metal
[11-12].
Figure 1 Principle of laser beam cutting (LBC)
Figure 1 illustrates a basic of the lasers cutting, which consisted of operating the main component such as laser
beam, focusing lens, pressurized gas inlet, laser jet and nozzle, etc [13]. Inside of the laser cutting, the gas will be
sprayed from the nozzle that is aligned with the laser or the lateral angle to the laser beam. There are two types of gases
used in the cutting process; active gas and inert gas respectively. The examples the active gas can be presented in terms
of nitrogen or air, while the inert gases are helium or argon, depending on the type of cutting material and the quality of
the cut. It can control the environment around the cutting area, the gas which came out from the nozzle blow can away
those of small parts from the melting objects. This makes the cuttings area smooth and clear. The gas usage in the laser is
oxygen therefore; the temperature could be raised higher from the oxidation effect. As a result, the speed and efficiency
of the cutting processes are improved. There are two laser beams projection; pulsed projection and continuous wave
(CW) projection. Moreover, there are a number of laser beams which can thus be different in the wavelength, as shown
in table 1 [14].
Table 1 Wavelength of laser types
Type of lasers Wavelength
4t
h
Harmonic of Nd: YAG 266 nm
3r
d
Harmonic of Nd: YAG 355 nm
2n
d
Harmonic of Nd: YAG 532 nm
Nd: YAG 1,064 nm
Fiber laser 1,074 nm
CO2 10,600 nm
The advantages of laser cutting are high cutting speed, narrow cut, low heat, low torque, low vibration and low gas
etc. However, some disadvantages of the laser cutting process are exploited in terms of heat, the proximity of the cutting
edge, the heat radiated from the cut area and electrical properties of the work piece. The impact of HAZ is considered in
the material cutting process [1]. However, the most common types of industrial laser cutting systems are including by:
Laser jet Nozzle
Work piece
Focusing lens
Laser beam
Pressurized gas
inlet
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Total
Reflector Flash Lamp
Nd:YAG Crystal
IN>
Flash Lamp
Power
Supply
Output
Coupler
VLNo-
Laser
Output
2.1 YAG Laser
Solid state lasers are constructed by doping a rare earth element or metallic element into a variety of host materials.
The most common host materials are Y3, A15, O12 and amorphous glass. The laser rod used in laser cutting is a synthetic
crystal of “Yttrium Aluminum Garnet (YAG)”. The YAG material is the host material that contains a small fraction of
neodymium, the active element. The YAG crystal is an ideal host for the lasing material Nd3+, being physically hard,
stable, optically isotropic, and has good thermal conductivity that permit laser operation at high average power levels.
Neodymium YAG is an excellent lasing material as it produces the highest level of powers than any other doping
element. The Nd: YAG laser is discussed due to it is the most common solid state laser that used in the industry.
Figure 2 Structure of YAG laser system
Figure 2 shows the structure of YAG laser system. In general, the Nd: YAG is a solid state laser. This means that
the medium is a solid crystal and it uses light energy as the pump source. Typical solid state lasers are pumped optically
by the arc lamps or flash lamps. The arc lamps typically are used for continuous wave (CW) pumping. However, the
flash lamps are operated with the pulsed lasers. Nowadays, the diode laser pumping is becoming increasingly popular
and will be opened the doors to receive new industrial applications [8], [13], [15-16].
2.2 CO2 Laser
A carbon dioxide laser is, generally, using a gas mixture of carbon dioxide (CO2), nitrogen (N2) and helium (He)
with a standard ratio of 1:1:10. The CO2 molecules constitute the active lasing medium, the N2 gas serves in an energy
transfer mechanism and the He atoms enhance the population inversion by depopulating the lower energy states. The
population inversion and lasing transition in a CO2 laser is established between vibrational and rotational energy states.
Most CO2 lasers are pumped by a high pressure electrical discharge.
Figure 3 Fundamental of CO2 laser system
Figure 3 shows a fundamental of CO2 laser system. The laser is, normally, requiring a lasing medium, power supply
and also a resonator cavity to sustain oscillation (back-front mirror). The lasing medium can, thus be obtained a CO2
glass tube system. The power supply would be excited atoms or molecules of the lasing medium to an upper energy state
by using electronic means or kinetic energy transfer. Laser transmission is initiated by spontaneous emission and
amplified by stimulating emission along the axis of the resonator cavity. The cavity mirrors have been reflected the
photons back and front through the laser medium for increased amplification. Energy is introduced into the laser through
the power supply, but only a fraction of the “wall plug” energy which is presented in the laser beam as it exits the front
Gas
Power suppl
y
Front mirror Back mirror Anode Cathode
Laser beam
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aperture. A typical laser might be less than 10% of the efficiently. Moreover, most of the energy is also lost in the form
of heat [17-18].
2.3 Fiber Laser
Fiber laser has been made huge advances in the recent years. Consequently, is not widely recognized in an
industrial tool, but will be implemented in some applications such as cutting, welding, piercing and drilling etc. It could
be enhanced by the development of more powerful lasers with high beam quality, efficiency and also stability. The
structure of fiber lasers has been shown in figure 4.
Figure 4 Principle of fiber laser system
Figure 4 illustrates the principles of fiber laser system. The high power of fiber laser system consists of a double
cladding, Ytterbium doped fiber, and also groups of multimode high power laser diodes respectively. The groups of
multimode pump diodes are coupled on the side of an active fiber. A coil of the active fiber with two Bragg gratings
form the laser medium. The Bragg gratings would thus be reflected particular wavelength of laser and transmit to the
others part of the system [8], [19-21].
The laser sources usage in the present estimation is including of Nd: YAG, CO2 and Fiber lasers. They are,
commonly, used in the industry for laser cutting applications. Table 2 is characterizing the comparison of difference laser
types for applying to the industry [22-23].
Table 2 Comparison in difference laser types for applying in industry.
Laser type
Characteristics Nd: YAG CO2 Fiber Laser
Lasing medium Crystalline rode Gas mixture Doped fiber
Wavelength (nm) 1,064 10,600 1,070
Beam transmission Fiber, lens Mirror lens Fiber, lens
Typical delivery fiber Ø (mm) 0.6 - 0.1-0.2
Output power (kW) Up to4 Up to 15 Up to 20
Typical beam quality (mm, mrd) 25 3.7 20
12 3.7 1.8
Maintenance interval (1,000 hours) 0.8-1.0 2 100
Power efficiency (%) 3-5 5-8 20-30
Approximate cost per kw (KS) 130-150 60 130-150
Foot print of the laser source Medium Large Small
Laser mobility Low Low High
kW laser cost (€/kW) 260 60 160
3. LASER CUTTING FOR INDUSTRIAL APPLICATIONS
Nowadays, the laser technology is beginning to play a greater role in the industrial sector. This is due to the
accuracy of the laser over other technologies. The laser cutting materials will result in less site effect, resulting in quality
products. Therefore, the industry is turning to lasers in the manufacturing process. Materials used for laser classification
can vary depending on the type of laser as shown in the following:
Multimode
pump diodes
stacks
Multimode
coupler
Laser beam
Laser generated Ytterbium doped fiber
Multimode
coupler
Fiber Bragg gratings
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3.1 Laser cutting steels
Most of thickness metal materials, such as metal plates or reinforced metal plates are, usually, cut by using the CO2
laser. It causes to the CO2 laser has higher energy level than the others. Normally, the thicker metal plates need higher
energy for the cutting process. According to the best of cutting process, we need to focus on the ratio between the
thickness and the strength of the material. The benefit of laser cutting can thus be created very small welds, even thinner
than the thickness of the material. The smallest could be one-fifth thinner than the material. For Nd: YAG laser, the
cutting material has to be thinner than twenty millimeter. However, the oxygen gas can be used to improve the cutting
efficiency and allows thicker material cutting. In this case, the laser has been used to raise material’s temperature.
Consequently, the oxygen gas is accelerated exothermic reaction in order to improve cutting efficiency. In terms of fiber
laser, there is a proof of 5 kW with 250 millimeter focus lens length with the thickness of 40 millimeters [24].
Figure 5 Fiber laser cutting machine and its output example
(Ref.: http://yueminglaser.sg/8-5-fiber-laser-cutting-machine-for-tubes-and-sheet-metal)
3.2 Laser cutting aluminum / Stainless steel
Carbon-aluminum and stainless steel are metals which are able to reflect the light and heated the conductor. This
may sometimes affects to the quality of laser cutting procedures. The best solution is to increase the energy level and use
pressurized the gas technology. However, the increasing of the energy level might be raised the budget on the connecting
tool, such as gas filters which are needed to be replaced more frequently. In literatures, there are some researches
experiments on parameters which is affected to the production quality, including kerf width, kerf deviation, kerf taper,
heat affected zone (HAZ), dross formation and surface roughness. For examples, Leone et al was studied on a suitable
parameter for the aluminum alloy 6061 T6 cutting with a power of 150 watt in the multimode pulsed laser machine [26].
Moreover, Tamizhmani et al was finding out the optimize parameters of 0.5-millimeter stainless steel for cutting with
small heat affected zone [1]. Furthermore, Amit and Vinod was designed a model for explaining to the cutting
procedures of aluminum alloy with thin sheet for straight and curved profile [11-12]. Consequently, Ambar et al was
investigated the most fitted parameters range of 4 to 20 millimeter stainless steel for cutting in the dry air and underwater
environment [27]. All of examples as mentioned above using only the Nd: YAG laser machine. Furthermore, Ahmet et
al was used few mathematical models for surface roughness prediction and width of heat affected zone in order to cut 3
millimeter and 4 millimeter of the alloy steels by using CO2 laser [6]. Finally, Rodrigues et al was finding out the best
parameters for 2 kW of the laser diode for cutting an 1 millimeter stainless steel [28].
Figure 6 Nd: YAG laser machining and its output examples
(Ref: http://www.domainlaser.com)
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E
3.3 Laser cutting the other material
Apart from steels, aluminum or stainless steels, laser cutting can be used on other materials including CO2 laser
cutting on thermoplastics (polymethylm - methacrylate, polycarbonate and polypropylene) with grey relational parameter
analysis (GRA) [29]. Furthermore, Riveiro et al was studied in CO2 laser for cutting with a parameter of 3 millimeter for
the carbon fiber reinforced plastics (CFRPs) and also 10 millimeter for the natural granite without affecting kerf width,
taper angle and width of the HAZ [30-31]. In addition, Bashir et al was investigated some experiments on Nd: YAG
laser cutting for nonmetallic such as paper, plastic, wood, cloth, glass, and rubber [32].
Figure 7 CO2 Laser cutting machine with some output from non-metal materials
(Ref: http://www.domainlaser.com)
4. APPLICATIONS OF LASER CUTTING IN THAILAND INDUSTRY
In Thailand, there are a few laser cutting were studied. For example, Nara was studied some experiments on the 4
millimeter stainless steel by using SUS304 laser and also employing ANOVA to analyze the power, frequency and also
cutting speed with 33 factorials [33]. In addition, Rittichai et al was used 23 factorials on a power, pressure gas and
cutting speed for cutting 6 millimeter stainless steel [34]. Further, Worawat et al was used the Nd: YAG laser machine
with more than 50 watt of power for investigating the suitable parameters of 2 sets of the mirrors curvature radius [35].
Furthermore, Chananchida et al was applied the cutting machine to create the artificial leather for the cloth patterns [36].
Figure 8 CO2 Laser cutting machine and its output examples
(Ref: https://thai.alibaba.com/product-detail/co2-laser-cutting-machine-price-for-textiles-clothing-fabric-60469235279.html)
5. CONCLUSIONS
Nowadays, the laser cutting technology is becoming more and more popular. It gains an important role, especially
for the industrial production. The benefits are improving the speed and accuracy for the production. This corresponds to
the end-products are impressive and cheapest. These results can thus be increased the number of the Thailand industries
to use this technology in their production lines. Laser cutting machines are able to cut the material with higher speed, less
heat, less vibration, less gas production, smaller cutting area and less twisted production, comparing to other cutting
technology. Unfortunately, it’s still expensive resulting in small number of the real usage. Accordingly, Thai government
should encourage and support those industries to use the machine, for examples, decreasing tax, educating the benefits,
encouraging industrial research collaborations.
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