Laser Cutting
Correct conditions
Good cut
If you are not getting a good cut from your laser you may be experiencing any of the following:
Troubleshooting checklist
Check and correct A Nozzle contamination Laser power and pulsing conditions Cutting speed Cutting gas Nozzle standoff Nozzle type, condition and alignment Material specification and condition Lens type, condition and alignment Beam steering mirror condition and alignment Laser mode quality and polarization B C D E F G H I J Time required (mins) 12 15 12 12 12 110 15 1020 560 per mirror 2040
This shows a good cut in 8mm mild steel. Smooth, square cut edge with a light scale of oxide.
Common faults
Dross
Effect Dross (oxygen & nitrogen cutting)
Problem Insufficient melt clearance Processing too fast evidence of curved drag lines Low pressure evidence of curved drag lines Low power Poor focus Nozzle too narrow
Action
A. Nozzle contamination
Reduce speed
Dirt or spatter on the nozzle may deflect the gas jet to one side Wipe the nozzle or replace if damaged Nozzle deflects will only result in a less efficient cutting process and do not pose a safety risk
Increase gas pressure Increase power Check lens Increase nozzle diameter
B. Laser power and pulsing conditions
1. Compare laser power and pulse settings to those used successfully on similar jobs 2. If power level is lower than usual: The laser may need time to warm up (up to 30mins) The helium supply is running low The laser needs tuning The laser needs servicing E.g. internal mirrors need to be cleaned Requires trained personnel
Side burning
C. Cutting speed
Compare cutting speed to those used successfully on similar jobs Try increasing and decreasing the speed by 10% and 20%
Effect Side burning (oxygen cutting) Problem Oxygen pressure too high Processing too slowly Damaged nozzle Action Reduce gas pressure Increase speed Check/replace nozzle
D. Cutting gas
1. Check the type of gas being used against similar successful jobs 2. Check supply pressure and flow Nozzle blockages will affect pressure and flow It is best to have both a flow meter and a pressure gauge Excessive oxygen pressure results in burning of corners and loss of fine details 3. Insufficient gas purity or gas supply contamination Contact your gas supplier Oxygen cutting: cutting speed reduced Nitrogen cutting: surface quality reduced
Cutting unequal in x-y plane
Effect Cutting unequal in x-y plane Problem Polarisation problems Damaged phase retarder Beam off centre Action Check and replace Align to nozzle
E. Nozzle material standoff
Compare to earlier successful results Normally the standoff is 0.25-2mm Changing non-identical nozzles may change stand-off Alter nozzle-lens distance to re-optimise process
Acknowledgements Dr John Powell LIA Guide to Laser Cutting (Pub: Laser Institute of America)
Laser Cutting
Material related fault F. Nozzle type, condition and alignment
1. Is the nozzle of the right type (exit diameter) for the job? 2. Is the nozzle worn or scratched? 3. Is the laser in the centre of the nozzle (i.e. centre of the gas jet)? If not: The machine will not cut equally well in all directions: Sparks may exit top of the cut zone when cutting in certain directions Reduction of sparks leaving the bottom of the cut when cutting in certain directions
Example of how material quality can affect cut quality oxygen cutting of low grade mild steel.
Nitrogen purity related faults
Nitrogen, 1% oxygen 0.1% oxygen cut edge oxidised 100 ppm oxygen 25 ppm oxygen Oxidation of the cut is evident at 100 ppm purity. The edge becomes rough at 0.1% purity (1000 ppm).
G. Material specification and condition
1. What is the material? 2. Is the condition of the material affecting the cutting? Surface coating (rust, paint, mill scale, etc.) Deep scratches
H. Lens type, condition and alignment
1. Is the right focal length lens being used? Is it fitted correctly? 2. Is the lens scratched or dirty? Both can give cutting problems Even if it is clean it may have become over-heated 3. Is the laser beam correctly aligned onto the lens? Beam steering mirrors may need re-alignment
Laser mode quality and polarisation
Good mode (TEM 00 )
I. Beam steering mirror condition and alignment
1. Are the mirrors clean? Take power readings after each one. Power losses should be below 5% per mirror 2. Alignment should be square and central Realignment of mirrors requires training
J. Laser mode quality and polarisation
1. The distribution of energy across the laser beam cross section is called its mode Poor mode quality results in poor cutting quality Laser mode identification and tuning require training 2. CO2 laser beam polarisation requires careful control for successful metal cutting If circular profiles are oval on the bottom but circular on top, the polarising mirror(s) may need cleaning or replacing
Bad mode
Gas consumption v. nozzle size
Perspex mode burn. Laser evaporation gives good 3D approximation of beam profile, but it requires practice for reproducability, and produces noxious fumes.
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