CO2 laser cutting of MDF: 1. Determination of process parameter settings

This paper details an investigation into the laser processing of medium-density fibreboard (MDF). Part 1 reports on the determination of process parameter settings for the effective cutting of MDF by CO₂ laser, using an established experimental methodology developed to study the interrelationship between and effects of varying laser set-up parameters. Results are presented for both continuous wave (CW) and pulse mode (PM) cutting, and the associated cut quality effects have been commented on.     

Optical fibre beam delivery of high-energy laser pulses: beam quality preservation and fibre end-preparation

This paper investigates the extension of optical fibre beam delivery to high-brightness applications, in particular laser percussion drilling, where both a good beam quality and high peak power are required. Beam quality preservation through a number of optical fibres is studied both experimentally and by using a ray propagation model. It is determined that in order to achieve the beam quality required for percussion drilling (M²<30) the largest fibre which can be used is 400 μm diameter. The laser-induced damage threshold is measured for a number of 400 μm fibres, and a CO₂ laser-annealing technique is shown to increase the damage threshold by a factor of 10, allowing 28 J, 1 ms pulses to be transmitted.     

Processing of concretes with a high power CO2 laser

Laser material processing, being a non-contact process, minimizes many of the complexities involved in the decontamination and decommissioning of nuclear facilities. A high power laser beam incident on a concrete surface can produce spalling, glazing or vaporization, depending upon the laser power density and scan speed. This paper presents effect of various laser processing parameters on the efficiency of material removal by surface spalling and glazing. The size of laser beam at constant fluence or energy density had significantly different effect on the spalling process. In thick concrete block cutting the flow or removal of molten material limits the cutting depth. By employing repeated laser glazing followed by mechanical scrubbing process cutting of 150 mm thick concrete block was carried out. Gravitation force was utilized for molten materials to flow out while drilling holes on vertical concrete walls. The dependence of the incident laser beam angle on drilling time was experimentally studied.     

CO2 laser cutting of ultra thin (75 µm) glass based rigid optical solar reflector (OSR) for spacecraft application

Present study reports for the first time laser cutting of multilayered coatings on both side of ultra thin (i.e., 75 µm) glass substrate based rigid optical solar reflector (OSR) for spacecraft thermal control application. The optimization of cutting parameters was carried out as a function of laser power, cutting speed and number of cutting passes and their effect on cutting edge quality. Systematic and in-detail microstructural characterizations were carried out by optical and scanning electron microscopy techniques to study the laser affected zone and cutting edge quality. Sheet resistance and water contact angle experiments were also conducted locally both prior and after laser cut to investigate the changes of electrical and surface properties, if any.     

A study of laser cutting engineering ceramics

A mechanical chopper Q-switched CO₂ pulse laser with high peak power, short pulse duration, high pulse repetition rate and moderate average power is developed. Using this laser, a multi-pass cutting process with high cutting speed is proposed for cutting hard and brittle materials such as engineering ceramics. Crack-free and fine cut is obtained in cutting Si₃N₄ ceramics. Moreover, the formation and elimination of the cracks are qualitatively analyzed in the paper.     

Use of the grey relational analysis to determine optimum laser cutting parameters with multi-performance characteristics

This paper presents an effective approach for the optimization of laser cutting process of St-37 steel with multiple performance characteristics based on the grey relational analysis. Sixteen experimental runs based on the Taguchi method of orthogonal arrays were performed to determine the best factor level condition. The response table and response graph for each level of the machining parameters were obtained from the grey relational grade. In this study, the laser cutting parameters such as laser power and cutting speed are optimized with consideration of multiple-performance characteristics, such as workpiece surface roughness, top kerf width and width of heat affected zone (HAZ). By analyzing the grey relational grade, it is observed that the laser power has more effect on responses rather than cutting speed. It is clearly shown that the above performance characteristics in laser cutting process can be improved effectively through this approach.     

Crack-free cutting of thick and dense ceramics with CO2 laser by single-pass process

This paper presents a laser crack-free cutting method of Al₂O₃ ceramics by single-pass process in internal straight and curve profiles. The thickness and theoretical density of the ceramics are up to 10 mm and about 99%, respectively. The effective cutting speed is about 0.23–0.42 mm/s corresponding to the laser head moving speed of 3 mm/s. The cutting process based on close-piercing lapping of piercing time of 0.1–0.5 s and piercing pitch of 0.03–0.05 mm is divided into two continuous stages. Appropriate time slot for each piercing, high peak power of 3500 W and low cycle duty (<30%) achieve crack-free cuts. Optimal cut quality parameters are analyzed and characterized. These results demonstrate that the laser crack-free cutting method is a promising method to achieve complex profiles of ceramic cuts.     

CO2 laser cutting of slate

Slate is a natural stone which has the characteristic that shows a well-developed defoliation plane, allowing to easily split it in plates parallel to that plane which are particularly used as tiles for roof building. At present, the manufacturing of slate is mostly manual, being noisy, powdery and unsafe for the worker. Thus, there is a need to introduce new processing methods in order to improve both the working conditions and the quality of the products made of slate.Following the previous work focused on the drilling and cutting of slate tiles using a Nd : YAG laser, we present in this paper the results of the work carried out to explore the possibilities to cut slate plates by using a CO₂ laser. A 1.5 kW CO₂ laser was used to perform different experiments in which, the influence of some processing parameters (average power, assist gas pressure) on the geometry and quality of the cut was studied. The results obtained show that the CO₂ laser is a feasible tool for a successful cutting of slate.     

Laser micro-processing of cardiovascular stent with fiber laser cutting system

A metallic cardiovascular stent cutting system based on fiber laser was designed in this study. In order to achieve the cutting of stent, the main modules and the key technologies were analyzed and achieved. Then with the cutting system, the kerf width size was studied for different cutting parameters including laser output power, pulse length, repeat frequency, cutting speed and assisting gas pressure. Finally, a high quality of cutting of 316L stainless steel cardiovascular stent was achieved.     

Lumped parameter model for multimode laser cutting

A lumped parameter mathematical model is developed to relate the cut depth to the laser cutting parameters and material properties. The model takes into account the threshold power of the incident laser beam for the initiation of cutting and modifies an earlier cutting model so that it applies to a wide set of process parameters ranging from low to high laser powers and slow to fast cutting speeds. Plain steel is taken as an example to show the effects of various process parameters such as the laser power, spot size and cutting speed on the cut depth. Special emphasis is given to the effect of laser mode structure on its cutting capability.     

Wedge cutting of mild steel by CO2 laser and cut-quality assessment in relation to normal cutting

In some applications, laser cutting of wedge surfaces cannot be avoided in sheet metal processing and the quality of the end product defines the applicability of the laser-cutting process in such situations. In the present study, CO₂ laser cutting of the wedge surfaces as well as normal surfaces (normal to laser beam axis) is considered and the end product quality is assessed using the international standards for thermal cutting. The cut surfaces are examined by the optical microscopy and geometric features of the cut edges such as out of flatness and dross height are measured from the micrographs. A neural network is introduced to classify the striation patterns of the cut surfaces. It is found that the dross height and out of flatness are influenced significantly by the laser output power, particularly for wedge-cutting situation. Moreover, the cut quality improves at certain value of the laser power intensity.     

Plasma modelisation and control for laser dismantling

Laser dismantling has been investigated for many years in several laboratories including the Photonics Systems Laboratory. However, until recently, material processing with high-power laser beams was not seriously considered as an acceptable alternative for nuclear power plant dismantling. Our laser dismantling approach associates optical technologies and target plasma modelization and control. In previous papers, we have reported on innovative digital diffractive engineering used for adapted light concentration. In this paper we introduce the plasma modelisation and control for which laser cutting at long distance without assist gas is now possible. We discuss the basic model that we have taken into account and we describe the mechanisms of laser material interaction with plasma formation that we have to deal with to optimise a laser dismantling process. We conclude with a discussion of optimized laser parameters to be used for efficient laser dismantling.     

Estimation of the most influential factors on the laser cutting process heat affected zone (HAZ) by adaptive neuro-fuzzy technique

Heat affected zone (HAZ) of the laser cutting process may be developed on the basis on combination of different factors. In this investigation was analyzed the HAZ forecasting based on the different laser cutting parameters. The main aim in this article was to analyze the influence of three inputs on the HAZ of the laser cutting process. The method of ANFIS (adaptive neuro fuzzy inference system) was applied to the data in order to select the most influential factors for HAZ forecasting. Three inputs are considered: laser power, cutting speed and gas pressure. According the results the cutting speed has the highest influence on the HAZ forecasting (RMSE: 0.0553). Gas pressure has the smallest influence on the HAZ forecasting (RMSE: 0.0801). The results can be used in order to simplify HAZ prediction and analyzing.     

Multiple-objective optimization in precision laser cutting of different thermoplastics

Thermoplastics are increasingly being used in biomedical, automotive and electronics industries due to their excellent physical and chemical properties. Due to the localized and non-contact process, use of lasers for cutting could result in precise cut with small heat-affected zone (HAZ). Precision laser cutting involving various materials is important in high-volume manufacturing processes to minimize operational cost, error reduction and improve product quality. This study uses grey relational analysis to determine a single optimized set of cutting parameters for three different thermoplastics. The set of the optimized processing parameters is determined based on the highest relational grade and was found at low laser power (200 W), high cutting speed (0.4 m/min) and low compressed air pressure (2.5 bar). The result matches with the objective set in the present study. Analysis of variance (ANOVA) is then carried out to ascertain the relative influence of process parameters on the cutting characteristics. It was found that the laser power has dominant effect on HAZ for all thermoplastics.     

Selection of the most influential factors on the water-jet assisted underwater laser process by adaptive neuro-fuzzy technique

Water-jet assisted underwater laser cutting has shown some advantages as it produces much less turbulence, gas bubble and aerosols, resulting in a more gentle process. However, this process has relatively low efficiency due to different losses in water. It is important to determine which parameters are the most important for the process. In this investigation was analyzed the water-jet assisted underwater laser cutting parameters forecasting based on the different parameters. The method of ANFIS (adaptive neuro fuzzy inference system) was applied to the data in order to select the most influential factors for water-jet assisted underwater laser cutting parameters forecasting. Three inputs are considered: laser power, cutting speed and water-jet speed. The ANFIS process for variable selection was also implemented in order to detect the predominant factors affecting the forecasting of the water-jet assisted underwater laser cutting parameters. According to the results the combination of laser power cutting speed forms the most influential combination foe the prediction of water-jet assisted underwater laser cutting parameters. The best prediction was observed for the bottom kerf-width (R² = 0.9653). The worst prediction was observed for dross area per unit length (R² = 0.6804). According to the results, a greater improvement in estimation accuracy can be achieved by removing the unnecessary parameter.     

Ultraviolet laser microstructuring of silicon and the effect of laser pulse duration on the surface morphology

The study of the laser pulse duration effect on the silicon micro-spikes morphology is presented. The microcones were produced by ultraviolet (248 nm) laser irradiation of doped Si wafers in SF₆ environment. The laser pulse duration was adjusted at 450 fs, 5 ps and 15 ns. We have analyzed the statistical nature of the spikes’ morphological characteristics, such as periodicity and apex angle by exploiting image processing techniques, on SEM images of the irradiated samples. The correlation of the quantitative morphological characteristics with the laser parameters (pulse duration, laser fluence and number of pulses) provides new insight on the physical mechanisms, which are involved on the formation of Si microcones.     

Optical focus control system for laser welding and direct casting

A non-intrusive optical sensor system has been developed for focus control of laser welding. This detects the light generated by the process through the laser delivery optics, and exploits the chromatic aberrations of these optics to detect any laser focal error at the workpiece. This system works for a wide range of materials and welding parameters, and example results are presented. The sensor has also been applied to laser ‘direct casting’, a process in which 3-D structures are built by flowing metal powder into a focused laser beam. In this case, melt pool temperature is also important, and so additional optics are incorporated into the sensor to provide a pyrometric temperature measurement which is used to control the laser power.     

The use of grey relational analysis to determine laser cutting parameters for QFN packages with multiple performance characteristics

This paper reports an application of the grey relational analysis (GRA) to directly optimize laser cutting of a quad flat non-lead (QFN) strip using six performance characteristics. The most important performance characteristics include the cutting depth, the width of heat affected zone (HAZ), and the width of cutting line for both epoxy and Cu+epoxy materials along the cutting path. During the GRA, higher grades are obtained from any of the deeper (more complete) cutting depth, reduced widths of the HAZ and reduced widths of the cutting line. From nine experiments based on the orthogonal array of L9(3⁴), a current of 29 A, a frequency of 2 kHz, and a cutting speed of 2 mm/s were found to be the best parameters for laser cutting of a QFN strip with a thickness of 0.9 mm. Moreover, the analysis of variance (ANOVA) is also employed to determine the contribution of each control parameter on the cutting quality characteristics. The three largest measured contributions on the cutting quality in decreasing order are the frequency, the current, and the cutting speed. Compared with the Taguchi optimization method, the GRA approach is significantly simpler because it directly assigns appropriate weighting factors to the required qualities. Finally, confirmation experiments are performed to ensure the robustness of the GRA predicted optimal configuration for laser cutting a QFN strip.     

A power ramped pulsed mode laser piercing technique for improved CO2 laser profile cutting

Laser piercing is one of the inevitable requirements of laser profile cutting process and it has a direct bearing on the quality of the laser cut profiles. We have developed a novel power ramped pulsed mode (PRPM) laser piercing technique to produce much finer pierced holes and to achieve a better control on the process parameters compared to the existing methodology based on normal pulsed mode (NPM). Experiments were carried out with both PRPM and NPM laser piercing on 1.5-mm-thick mild steel using an in-house developed high-power transverse flow continuous wave (CW)-CO₂ laser. Significant improvements in the spatter, circularity of the pierced hole and reproducibility were achieved through the PRPM technique. We studied, in detail, the dynamics of processes involved in PRPM laser piercing and compared that with those of the NPM piercing.     

Laser cutting speeds for ceramic tile: a theoretical–empirical comparison

This paper presents a comparison of theoretically-predicted optimum cutting speeds for decorative ceramic tile with experimentally-derived data. Four well-established theoretical analyses are considered and applied to the laser cutting of ceramic tile, i.e. Rosenthal's moving point heat-source model and the heat balance approaches of Powell, Steen and Chryssolouris. The theoretical results are subsequently compared and contrasted with actual cutting data taken from an existing laser machining database. Empirical models developed by the author are described which have been successfully used to predict cutting speeds for various thicknesses of ceramic tile.