Is Laser Cutting Suitable for Metal Processing?

Since its first application in the 1960s, laser cutting technology has experienced rapid technological development and widespread industry popularization. Initially, laser cutting was mainly used in aerospace and military fields, but with the maturity of laser technology, the reduction of equipment costs and the continuous innovation of manufacturing processes, it has gradually penetrated into various industrial fields and become a core technology of the modern processing industry. Especially in the field of metal processing, laser cutting meets the growing market demand with its unique accuracy, speed and flexibility.

In metal processing, laser cutting, as a highly efficient way of processing materials, provides producers with excellent cut quality and extremely high material utilization. Whether it's a complex part process or a high-volume production task, laser cutting machines are able to accomplish the cutting task quickly and accurately. This technology not only reduces production cycle time, but also reduces the need for follow-up processing, further enhancing productivity.

Laser cutting has an extremely wide range of applications in metal processing, covering a wide range of fields such as machinery manufacturing, automotive industry, construction engineering and art design. It can cut a variety of metal materials, including stainless steel, carbon steel, aluminum and copper alloy, etc., applicable to a variety of thickness cutting needs. With the advancement of Industry 4.0 trend, the automation and intelligence of laser cutting technology will further promote the innovative development of metal processing. Therefore, for the manufacturing industry, mastering and applying laser cutting technology has become an important factor to enhance competitiveness.

| Basic Principles of Laser Cutting

A laser (Light Amplification by Stimulated Emission of Radiation) is a type of light that is formed by the amplification of excited radiation. Laser beams are highly monochromatic, coherent and directional, which allows the laser to propagate over long distances in the atmosphere with concentrated energy. In a laser, an excitation medium (e.g. gas, solid or liquid) is excited to produce photons, which are reflected by mirrors to form extremely intense laser beams. These laser beams can be focused through a lens to a very small cutting point, resulting in a high energy density focus.

During the laser cutting process, the laser beam is focused onto the surface of the metal material and the laser energy is converted into thermal energy, which rapidly raises the temperature of the material. At this point, the material reaches its melting point and eventually melts or vaporizes. An auxiliary gas (such as oxygen, nitrogen or air) is often added to the cutting process. The auxiliary gas not only helps to remove the molten metal, but also affects the quality and speed of the cut. The chemical reaction that occurs with the aid of oxygen creates a high temperature that helps to cut thicker metal materials more efficiently.

| Types of Laser Cutting Equipment

Laser cutting equipment can be categorized into several main types depending on the laser source:

CO2 Laser Cutting Machine

CO2 laser cutting machines are devices that use carbon dioxide gas as the laser medium and are suitable for cutting non-metallic materials. Its advantages are relatively low cost and good cutting quality, but relatively low power and low efficiency in handling metal materials with large thickness. In addition, the efficiency of CO2 lasers is about 20%-25% at high power.

Fiber Laser Cutting Machine

Fiber laser cutting machines use optical fibers as the laser medium, providing high efficiency, high density and excellent beam quality. Compared to CO2 lasers, fiber laser cutting machines have an electrical energy conversion efficiency of 70%-80%, allowing them to cut thicker metal materials and at a much faster speed. Another advantage of fiber laser machine is that it occupies less space and has low maintenance cost, which makes it a more popular laser cutting equipment in the current market.

Nd:YAG Laser Cutting Machine

Nd:YAG (Neodymium Doped Aluminum Garnet) laser cutting machines use solid-state lasers and are suitable for cutting applications that require high energy pulses. Due to their good beam quality and high energy output, Nd:YAG lasers are suitable for precision cutting and welding, and excel especially in high-end applications such as aerospace and medical devices. However, Nd:YAG machines are larger and have relatively high maintenance costs compared to fiber laser cutters.

In conclusion, laser cutting technology has become an important tool for modern metal processing, and various types of laser cutting machines meet the industry's different needs for cutting efficiency, quality and flexibility. Choosing the right laser cutting equipment will have a direct impact on production efficiency and product quality. Click here to contact Suntop Laser today for more information on laser cutting machines.

| Applicable Metal Materials

Laser cutting technology can be used to process a wide range of metal materials, including but not limited to:

| Cutting Thickness Range

The applicable thickness of laser cutting varies depending on the type of material, and different cutting thicknesses can be realized with different powers of cutters:

Power	Carbon steel (mm)		Stainless steel (mm)		Aluminum (mm)		Brass (mm)
	Ultimate thickness	Actual processing thickness	Ultimate thickness	Actual processing thickness	Ultimate thickness	Actual processing thickness	Ultimate thickness	Actual processing thickness
1KW	12	8	6	4	4	2	3	2
2KW	16	10	8	6	6	4	6	4
3KW	22	12	11	8	8	6	8	6（4）
4KW	25	14	12	10	10	8	10	8（5）
6KW	25	16	20	14	16	10	12	10
8KW	40	20	30	18	30	16	16	12
12KW	40	22	40	25	40	20	16	16
15KW	60	25	50	30	50	25	20	18

The table above has listed the tables corresponding to different powers in detail (only for reference). Each material corresponds to the limit thickness and the actual processing thickness. Generally, the thickness of the cut processed by the factory in batches should be based on the actual processing thickness. This will not only guarantee the laser equipment service life and also ensure that the processed materials have good accuracy. If you encounter too thick a plate, you can also cut it, but it must not exceed the limit thickness. If cutting plates of extreme thickness in batches, after a long time, there will be certain errors in the materials, and the life of the laser will be shortened.

| Cutting Efficiency & Quality

The efficiency and quality of laser cutting are important indicators for evaluating its application in the metalworking industry, both of which have a direct impact on the economics of production and the quality of the finished product. Various aspects of cutting efficiency and cutting quality are described in detail below.

1. Cutting efficiency

Cutting efficiency is mainly related to the following factors:

● Cutting speed:

The speed of laser cutting usually depends on the power of the laser, the thickness and type of material. Higher power lasers can achieve faster cutting speeds.

Cutting speed varies from material to material, for example, carbon steel is usually cut at a higher speed than stainless steel and aluminum.

● Laser power:

Cutting efficiency is usually proportional to the output power of the laser. Higher power lasers can cut thicker materials in the same amount of time, increasing productivity.

Modern high power laser cutting machines (e.g. 3000W, 6000W and even 10000W) have been able to achieve fast and efficient cutting of thick plates.

● Material type:

Differences in heat reflectivity, thermal conductivity and melting point of different materials affect the efficiency of laser cutting. For example, aluminum has better thermal conductivity, which may lead to heat diffusion when cutting, reducing cutting speed.

● Cutting Technology:

The auxiliary gas used in the cutting process and the cutting method (e.g., pulsed mode, continuous mode, etc.) can also affect efficiency. Using the right auxiliary gas (oxygen, nitrogen, etc.) can improve cutting speed and quality.

● Degree of automation:

A highly automated laser cutting system can manage the production process more effectively, thus improving overall cutting efficiency.

2. Cutting quality

Cutting quality is another key indicator for assessing the effectiveness of laser cutting, mainly including the following aspects:

● Cutting accuracy:

Laser cutting machine can achieve very high positioning accuracy, usually within ± 0.1 mm error, which makes its performance in complex graphics and fine cutting is particularly outstanding.

The level of cutting accuracy also depends on factors such as the adjustment of the laser and the way the material is mounted.

● Cutting edge quality:

Laser cutting has a smooth cutting edge and usually requires no subsequent processing. The cut produces fewer burrs and the kerf has a high degree of perpendicularity and finish.

Different auxiliary gas choices and cutting parameters (e.g., focus position, cutting speed, etc.) directly affect edge quality.

● Heat affected zone (HAZ):

Heat propagation during the cutting process may affect the material properties in the cutting area, creating a heat affected zone. A smaller heat affected zone reduces material deformation and hardening, thus increasing the feasibility of subsequent processing.

Efficient laser cutting reduces this zone, thereby maintaining the physical properties of the material.

● Cutting shapes and complexity:

Laser cutting can easily handle complex geometries and subtle patterns, greatly expanding design possibilities.

For example, laser cutting can be utilized to achieve outstanding 3D effects or specially shaped parts.

● Post-processing needs:

A high-quality cutting surface not only reduces the time for post-processing grinding and treatment, but also reduces processing costs and improves overall productivity.

3. Parameters affecting cutting efficiency and quality

● Laser wavelength and focus:

Reasonable control of the laser wavelength and focus point position can optimize the cutting effect. Focus position is too high or too low will affect the cutting effect.

● Cutting speed and power ratio:

Reasonable setting of cutting speed and laser power ratio is very critical. Too fast a speed may lead to incomplete cutting, too slow may lead to the expansion of the heat-affected zone.

● Material thickness:

As the material thickness increases, the cutting time will increase accordingly, so there is a need to balance between thickness and processing efficiency.

● Operator experience:

Experienced operators are able to reasonably adjust parameters according to material properties, equipment status and cutting needs to achieve higher efficiency and quality.

In industrial production, laser cutting is widely used because of its high efficiency and high quality, which can meet the needs of various complex designs and mass production. By continuously optimizing the cutting parameters, improving the machine performance and increasing the operating experience, the efficiency and quality of cutting can be further improved, thus promoting the continuous development of the metal processing industry. Click here to contact Suntop Laser today to learn more about laser cutting.

| Cutting Processes

Laser cutting usually adopts gas-assisted cutting (such as oxygen and nitrogen) to improve the cutting effect:

1. Oxygen cutting

Applicable materials: mainly used for cutting carbon steel.

Working principle: In the cutting process, the laser beam heats up the surface of the material, and the auxiliary oxygen will react with the melted metal to form an oxidation reaction to release more heat. This process improves the cutting speed and gives better quality cuts.

Advantages:

Faster cutting speed: the combustion of oxygen generates additional heat and facilitates the cutting process.

High quality of cut: fewer burrs and melt drops, smooth surface.

Economical: Oxygen cost is relatively low and cutting efficiency is high.

Disadvantages:

Since the oxidation reaction may cause oxidation of the cutting edge, it is less suitable for applications that require higher surface quality after cutting.

2. Nitrogen cutting

Applicable materials: mainly used for cutting materials such as stainless steel and aluminum.

Working principle: In laser cutting, nitrogen is used as a protective gas to avoid material oxidation, and at the same time reduce the heat-affected zone and effectively control the thermal deformation of the edge.

Advantages:

Avoiding oxidation: the material will not affect the surface quality due to oxidation during the cutting process, which is suitable for high precision requirements.

Reduction of thermal influence: deformation and stress at the cutting edge are reduced by cooling action.

Adaptable: can be used for a wide range of metal materials, especially suitable for those applications that require high surface quality.

Disadvantages:

Relatively high cost, nitrogen supply adds some processing costs compared to oxygen.

When choosing gas-assisted cutting, it is necessary to reasonably choose oxygen or nitrogen as the auxiliary gas according to the nature of the material to be cut, the required cutting quality and economic considerations. Both have their applicable scenarios and advantages and disadvantages in order to realize the best cutting effect in the laser cutting process.

Laser cutting technology is widely used in the field of metal processing due to its high precision, efficiency and versatility. Following are some of the major application areas of laser cutting metal processing:

1. Manufacturing

Automotive industry: for cutting body structure parts, components and decorative parts to meet the demand for lightweight and high strength.

Mechanical equipment manufacturing: in the production of castings, mechanical parts and equipment frames, laser cutting can achieve high precision cutting.

2. Sheet metal processing

Sheet metal parts production: Widely used in the manufacture of sheet metal parts, including chassis, shells, brackets, etc., capable of quickly cutting out complex shapes.

Customized production: small batch customization based on customer demand, flexible and efficient.

3. Packaging Industry

Packaging equipment: used to cut and process metal frames and parts of packaging machinery to meet the needs of different shapes and sizes.

4. Electrical and electronic industry

Electronic components: used to cut complex shapes of electrical equipment shells, connectors, heat sinks, etc. to ensure high precision and surface quality.

Circuit board processing: some special materials for circuit board cutting can also use laser technology.

5. Aerospace

Aerospace parts: in aircraft manufacturing, laser cutting can cut high-strength alloy materials to ensure cutting accuracy and surface finish.

Spacecraft components: for precision machining of spacecraft shells and structural parts.

6. Elevator and escalator industry

Elevator parts: laser cutting technology is widely used in the processing of structural parts, guide rails, door frames and other parts of elevators and escalators.

7. Furniture manufacturing

Metal furniture: It is used to cut parts of metal furniture (such as tables, chairs and storage cabinets, etc.) to enhance the aesthetics and personalization of the design.

8. Medical Equipment

Medical Device Manufacturing: Laser cutting is used to produce advanced medical devices and tools, such as surgical instruments, implants, etc., with high resource utilization and high hygiene requirements.

9. Art and decoration

Metal sculpture and artwork: Laser cutting can be used to produce intricate metal artwork, decorative objects, and metal decorative elements in high-end architecture.

Customized billboards: laser cutting enables fine text and pattern cutting, which is suitable for commercial advertising and signage production.

10. Construction

Architectural Decoration: Laser cutting is used in the manufacture of metal screens, balcony railings, door and window frames, etc. in building facades and interior decoration.

Laser cutting technology has become an important metal processing method in many industries due to its outstanding advantages. Click here to contact Suntop Laser today for more information.