applied

sciences
Article
Influence of Process Parameters in Laser Piercing
Sonia M. Garcia 1, *, Joana Ramos 1 , Aitzol Lamikiz 2 and Jordi Figueras 1
1 IK4-IDEKO Research Center, Pg. Arriaga 2, 20870 Elgoibar, Spain
2 Department of Mechanical Engineering, University of the Basque Country ETSI, ETSII-UPV,
c/Alameda de Urquijo s/n, 48013 Bilbao, Spain
* Correspondence: sgarcia@ideko.es; Tel.: +34-943748000




Received: 4 July 2019; Accepted: 31 July 2019; Published: 8 August 2019


Abstract: This work addresses the analysis of the influence of process parameters in laser piercing
for mild steel, stainless steel, and aluminum thick sheets, carried out by the monitorization of the
signal with a photodiode installed coaxially in the cutting head. The sensor captures the infrared or
visible signal emitted during the piercing. The relationship between the intensity of the signal and the
parameter values was analyzed, distinguishing between soft and fast piercings. The results permit the
optimization of the piercing strategy with a reduction of 25% in time and the possibility of establishing
a threshold to control the piercing process. This study reveals the importance of knowing parameter
dependencies with the process results and highlights the potential of monitorization systems in laser
cutting to improve the piercing duration and avoid wasting time during production.

Keywords: laser cutting; laser piercing; monitoring; piercing time; photodiode

1. Introduction
Piercing and laser cutting are two independent processes in which material evacuation have
different mechanisms [1,2]. In the piercing, the laser beam is stationary with respect to the workpiece
and the melt material is ejected upwards. In contrast, in the cutting process, the workpiece and
the laser beam move with respect to each other and the material goes downwards. In laser cutting
researchers focus on [3–7] dynamic phenomena and quality detection during the laser cutting progress.
They presented that the main reason for adherent material was related to melt ejection on the walls of
the kerf, showing that the optimal cutting speed for defect-free and low bottom roughness related
to the striation formation in the sidewalls of the kerf could be determined. Less work was reported
in cut interruptions or quality detection by photodiodes or visual monitoring. Authors developed
algorithms based on single or dual photodiodes for laser cutting monitoring, detecting successfully cut
interruptions in cuts of stainless steel, mild steel, and aluminum [8–10].
Regarding piercing processes, Rao et al. [11] worked on analyzing the influence of the parameters
on the piercing appearance. The authors developed a new piercing technique known as PRPM (power
ramped pulsed mode) obtaining smaller piercing holes with greater circularity and less ejected material
than in normal pulse mode. In mild steel, researchers [2,11] observed that increasing the power of
the peak or the duty cycle, increased the size of the hole and the irregularity of its shape and ejected
material, also obtaining wider piercings with oxygen assist gas than with nitrogen. Pocorni et al. [12]
investigated the piercing process in the laser cutting of stainless steel, demonstrating that appropriate
laser power modulation settings could considerably reduce both the piercing time and the required
energy to generate the piercing hole, also affecting its size.
To monitor piercing processes, technical approaches based on camera-based sensors, optical
sensors, and acoustic-based systems have been reported. Rao et al. [11] monitored the piercing duration
using two photodiodes and an oscilloscope that captured the visible spectrum, determining that the

Appl. Sci. 2019, 9, 3231; doi:10.3390/app9163231 www.mdpi.com/journal/applsci

Appl. Sci. 2019, 9, 3231 2 of 10

signal was low during the beginning and increased slowly with time due to the increase in the power
Appl. Sci. 2019, 9, x FOR PEER REVIEW 2 of 10
of the peak during the ramp. De Keuster et al. [13] performed an analysis of the piercing process using
a photodiode
that the signalor a was
microphone.
low duringThey observedand
the beginning thatincreased
the signal dropped
slowly withto negligible
time due to thevalues when
increase in the
piercing was achieved. Using the photodiode, the obtained signal was less
the power of the peak during the ramp. De Keuster et al. [13] performed an analysis of the piercing susceptible to unwanted
contributions
process using since it was located
a photodiode or a inside
microphone.the head,
Theyavoiding
observed sources
that the of noise
signal such as
dropped toambient
negligiblelight.
The values
acoustic signal
when theneeded
piercingtowasbe filtered
achieved. andUsing
processed because it captured
the photodiode, the obtained noise fromwas
signal the less
cutting
process (i.e., gas
susceptible toflow, laser).contributions
unwanted Kek et al. [14],sincethrough an analysis
it was located inside of theacoustic-emission
head, avoiding sources signals, found a
of noise
good such as ambient
agreement light. The
between the acoustic
quality of signal needed
a laser to bethe
cut and filtered
number andofprocessed because
bursts after it captured of
the termination
noise from the cutting process (i.e., gas flow, laser). Kek et al. [14],
laser cutting. The present work is an experimental study based on the analysis of the influencethrough an analysis of acoustic-of the
emission signals, found a good agreement between the quality of
process parameters in laser piercing with the aim of optimizing piercing duration. The useda laser cut and the number of bursts
tool is a
after the termination of laser cutting. The present work is an experimental study based on the analysis
monitoring system provided with a photodiode capable of capturing visible and infrared spectrum.
of the influence of the process parameters in laser piercing with the aim of optimizing piercing
The monitored signal intensity is evaluated and related to changes in piercing process parameters
duration. The used tool is a monitoring system provided with a photodiode capable of capturing
for mild steel, stainless steel, and aluminum thick sheets. Actually, it is possible to find commercial
visible and infrared spectrum. The monitored signal intensity is evaluated and related to changes in
devices to detect
piercing process theparameters
end of the forpiercing [15–17]
mild steel, or to optimize
stainless steel, and italuminum
by adjusting
thickonly laser
sheets. power it
Actually, [18–20],
is
or scientific studies on piercing that are focused on investigating the relationship
possible to find commercial devices to detect the end of the piercing [15–17] or to optimize it by between process
parameters
adjustingand onlypiercing appearance
laser power [18–20], [2,11,12].
or scientificThis workonwill
studies contribute
piercing that aretofocused
creatingonknow-how
investigating on the
influence of process between
the relationship parameters in laser
process piercing,and
parameters to improving their duration
piercing appearance and the
[2,11,12]. Thisdevelopment
work will of
newcontribute
piercing strategies
to creating thanks to the possibility
know-how of efficiently
on the influence modifying
of process the piercing
parameters in laser parameters
piercing, to based
improving their
on parameter dependencies. duration and the development of new piercing strategies thanks to the possibility of
efficiently modifying the piercing parameters based on parameter dependencies.
2. Experimental Section
2. Experimental Section
2.1. Laser Cutting System
2.1. Laser Cutting System
In this study, the experiments were carried out using a 5000 W fiber laser (IPG Photonics, Oxford,
MA, USA). In this
The study,
laser beamthe experiments
was carriedwere carried
by a 100 µm out using optical
diameter a 5000 fiber
W fiber
to thelaser (IPG head
cutting Photonics,
(Precitec
Oxford, MA, USA). The laser beam was carried by a 100 μm diameter
ProCutter, Germany) in which a 125 mm focal lens was used, resulting in a diameter spot optical fiber to the cutting headlaser
(Precitec ProCutter, Germany) in which a 125 mm focal lens was used, resulting in a diameter spot
of 125 µm when focusing on the workpiece (Figure 1). The monitorization was made by a sensor
laser of 125 μm when focusing on the workpiece (Figure 1). The monitorization was made by a sensor
system installed coaxially to the nozzle in the cutting head; specifically, a sandwich consisted of a
system installed coaxially to the nozzle in the cutting head; specifically, a sandwich consisted of a Si-
Si-diode (400–1100 nm) and a InGaAs-diode (1000–1800 nm), registering visible or infrared spectrum.
diode (400–1100 nm) and a InGaAs-diode (1000–1800 nm), registering visible or infrared spectrum.
The The
photodiodes
photodiodes detected
detected the molten
the moltenmeltmeltand
and vapor plumegenerated
vapor plume generated bybythethe piercing
piercing andand converted
converted
it into an analog
it into signal
an analog signalthat
thatwas
wasused
usedtotoanalyze
analyze the piercingprocedure.
the piercing procedure.Filters
Filters were
were installed
installed in the
in the
laserlaser
cutting head to avoid the registration
cutting head to avoid the registration of of the laser pointer and reflected laser irradiation
laser pointer and reflected laser irradiation signals. signals.
DataData
waswas acquired
acquiredthrough
through the
theoscilloscope
oscilloscope integrated intothe
integrated into theFagor
Fagor CNC
CNC 80708070 (Fagor
(Fagor Automation,
Automation,
Basque
Basque Country,
Country, Spain)
Spain) installedininthe
installed thelaser
lasercutting
cutting system.
system.TheThesample
sample rate was
rate 500500
was Hz,Hz,
limited by by
limited
the CNC
the CNC cyclecycle duration.The
duration. Theassisting
assisting gases
gases were
were nitrogen
nitrogenand
andoxygen,
oxygen, with
with a purity
a puritygreater thanthan
greater
99.999%,
99.999%, flowing
flowing coaxially
coaxially totothe
thelaser
laserbeam.
beam. Gas
Gas nozzles
nozzles(Precitec,
(Precitec,Germany)
Germany) with a diameter
with a diameterof 2.5
of 2.5
and 3 mm
and 3 mm were used.were used.

Figure1.1.Scheme
Figure Scheme of the
the experimental
experimentalset-up.
set-up.
Appl. Sci. 2019, 9, 3231 3 of 10

2.2. Design of Experiments

The study was made with 20 mm thick sheets of mild steel (MS) and stainless steel (SS) and
aluminum of 10 mm thick. The pressure, standoff, focal position, duties, and ramp time were varied
to analyze their influence on the piercing process. Duties were used to reduce the energy, since they
were related to the percentage that the laser pulse was turned on/off. By modifying duties and ramp
time it was obtained frequency variation according to the selected percentages and time. Experiments
were repeated at least three times to check stability. After finding the ideal parameters for the piercing
process, to evaluate its functionality, a test pattern to be cut consisting on a rectangular piece of
25 × 30 mm2 with rounding corners (radius 4 mm) was chosen. The selection of infrared or visible
signal in the monitorization for each material was based on previous laser cutting works, where each
experiment was monitored with both signals. It was found that cuts with oxygen gas and nitrogen gas
displayed better signals with visible and infrared spectra, respectively. In this paper, mild steel and
aluminum are monitored with reference to the visible signal and stainless steel to the infrared signal.
While infrared signal was related to temperature, the visible signal was explained as a consequence
of vapor plume formation. Table 1 shows the ideal parameters for the three piercings. For MS, three
consecutive piercings were needed to avoid explosions during the process.

Table 1. Piercing parameters for mild steel 20 mm thick and stainless steel and aluminum 10 mm thick.

Piercing Parameters Mild Steel Stainless Steel Aluminium

Gas type O2 O2 O2 N2 O2
Power [W] 5000 5000 5000 5000 5000
Piercing time [ms] 7000 7000 3000 100 1000
Gas pressure [bar] 3 3 3 12 10.5
Focal [mm] −3 −5 −7 −3 −3
Standoff [mm] 8 8 8 4 3.5
Frequency [Hz] 500 500 500 5000 5000
Duty minimum [%] 8 14 20 40 20
Duty maximum [%] 14 20 20 40 20
Ramp time [ms] 1000 1000 1000 100 1000
Nozzle diameter [mm] 3 3 3 2.5 2.5

3. Results and Discussion

To analyze the results and based on the duration, the piercing process was divided into soft
piercing and fast piercing, establishing the division in >1.5 s or less, respectively. Whereas in stainless
steel and aluminum it was possible to develop a fast piercing, in mild steel, due to its thicker thickness
(20 mm), a more gradual piercing process was required, taking longer than 1.5 s. In both cases, the
signal intensity dropped drastically when piercing pierced the sheet, indicating the final stage of the
process (when it is less than the programmed one) or the final stage of the programmed duration.
It was observed that the programmed time was higher than the real needed time to pierce the sheet.
Parameter influence determination done by the evaluation of signal monitorization optimized the
piercing duration, requiring less time for the cutting process to continue. In the results, it was observed
that a more intense signal did not imply that the piercing went through the metal sheet sooner. Soft
piercing tests showed noisier signals due to lower frequency working values.

3.1. Soft Piercing

The influence of the programmed parameters in soft piercing processes of mild steel was studied,
observing the visible signal intensity and, consequently, the vapor plume formation. It was observed
that the signal value remained constant with the focal position and standoff variations (Figure 2;
however, it varied for the rest of the parameters (Figure 3). Monitoring results showed that the vapor
plume formation depended on parameters directly related to laser power, such as duties or ramp time,
Appl. Sci.
Appl. Sci.2019, 9,x3231
2019,9, FOR PEER REVIEW 44 of
of 10
10

or ramp time, or on the material ejection produced by the gas. The selected pressure mainly affected
or on
the the material
beginning ejection
of the process,produced by the
which had gas. The
a lower selected
signal with pressure
less gas mainly
pressureaffected
due tothelessbeginning
material
of the process, which had a lower signal with less gas pressure due to less
evacuation and, finally, matching the signal value as the process continued and the vapor plume material evacuation and,
finally, matching
formation becamethe signalAs
steady. value
the as the process
duties continued
increased, the valueandofthethevapor plume visible
monitored formationsignalbecame
also
steady. As the duties increased, the value of the monitored visible signal
increased, while from achieving a given value (20) the same signal intensity was always obtained. also increased, while fromIt
achieving
was a giventhat
also observed valuethe(20)
ramp thetime
same signal
of the firstintensity was always
piercing affected obtained.of It
the intensity thewas alsoHowever,
signal. observed
that the from
starting rampatime of the
similar firstfirst piercing
piercing, theaffected
ramp time the of
intensity
the secondof the signal.did
piercing However,
not affectstarting from a
the intensity
similar first piercing, the ramp time of the second piercing did not affect
of the signal. The same explanation as for pressure could be applied for these last two studies, the intensity of the signal.
The same explanation
attributing the initial as for pressure
variation could be
of signal appliedto
intensity forthe
these last two
plume studies, and,
formation attributing the initial
afterward, the
variation of signal intensity to the plume formation and, afterward, the obtaining
obtaining of a fixed intensity value to its saturation. Figure 3b,c showed lower signal intensities of a fixed intensity
for
value toduties
8-14-18 its saturation. Figure
percentages, and3b,c showed lowerand
1000-1000-1000 signal intensities for
1000-500-1000 ramp8-14-18 duties
times, percentages,
respectively. and
In these
1000-1000-1000
cases, and 1000-500-1000
process conditions were softer ramp
and,times, respectively.
thus, the In theseconstant
plume remained cases, process
without conditions
saturating. were
softer and, thus, the plume remained constant without saturating.

1000
Visible signal intensity [u.a.]

800

600

400

200 3 mm
0 mm
- 3 mm
0
0 2000 4000 6000 8000

Time [ms]

(a)

1000
Visible signal intensity [u.a.]

800

600

400 8 mm
3 mm
2 mm
200
1 mm
0,8 mm
0
0 2000 4000 6000 8000

Time [ms]

(b)
Figure 2.
Figure Piercingmonitored
2.Piercing monitoredsignal
signalfor
formild
mildsteel
steel20
20mm
mmthick,
thick,varying
varying(a)
(a)focal
focalposition;
position;(b)
(b)standoff.
standoff.
Appl. Sci. 2019, 9, x FOR PEER REVIEW 5 of 10
Appl. Sci. 2019, 9, 3231 5 of 10

1000
Visible signal intensity [u.a.]

800

600

400

5 bar
200 3 bar
1 bar
0
0 2000 4000 6000 8000 10000 12000 14000 16000 18000

Time [ms]

(a)

1000
Visible signal intensity [u.a.]

800

600

400

8-14-18 %
200
12-16-20 %
14-16-22 %
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

Time [ms]

(b)

1200
Visible signal intensity [u.a.]

1000

800

600

400
1000-1000-1000 ms

200 500-1000-1000 ms
1000-500-1000 ms
0
0 2000 4000 6000 8000 10000

Time [ms]

(c)
Figure 3.
Figure 3. Piercing
Piercing monitored
monitored signal
signal for mild steel 20 mm thick, varying (a) pressure;
pressure; (b)
(b) duties
duties
percentage; (c)
percentage; (c) ramp
ramp time.
time.
Appl.
Appl. Sci.
Sci.2019,
2019,9,9,x3231
FOR PEER REVIEW 66of
of10
10

3.2. Fast Piercing

3.2. Fast Piercing
For stainless steel and aluminum thick sheets, a fast piercing process was required. The tests
showed Forthat the monitored
stainless steel andsignals
aluminum did not
thickhave a clear
sheets, relationship
a fast with thewas
piercing process programmed
required. values of
The tests
the piercing
showed thatparameter.
the monitoredHowever,
signalsindidboth
notsamples idealrelationship
have a clear parameters with
displayed intensity signals
the programmed valuesin of
a
determined range, making it possible to establish a threshold to control the piercing
the piercing parameter. However, in both samples ideal parameters displayed intensity signals in a process.
In the case
determined of stainless
range, making itsteel (Figure
possible to 4), the infrared
establish monitored
a threshold signalthe
to control ofpiercing
ideal process conditions
process.
(blackInline) always
the case gave offsteel
of stainless a lower intensity
(Figure than the monitored
4), the infrared non-ideal signal
ones. In of this
idealsense,
processand relating
conditions
infrared signal
(black line) and temperature,
always it could
gave off a lower be explained
intensity than thethat good piercing
non-ideal ones. conditions generated
In this sense, lower
and relating
intensity due toand
infrared signal a lower temperature,
temperature, thanks
it could to havingthat
be explained a minimum heating
good piercing in the piercing
conditions zone.lower
generated
In aluminum
intensity piercing
due to a lower processes,thanks
temperature, the usetoofhaving
parameter values heating
a minimum that involve
in thean increase
piercing in laser
zone.
power-provoked
In aluminumexplosions, saturatingthethe
piercing processes, usevisible monitored
of parameter signal
values that(Figure
involve5)an due to theinvapor
increase laser
plume formation.explosions,
power-provoked The signal intensity
saturatingdisplayed
the visiblehigher valuessignal
monitored than the ideal5)parameters
(Figure when plume
due to the vapor it was
saturated
formation.asThea consequence of the
signal intensity explosion
displayed of material.
higher values than the ideal parameters when it was saturated
Table 2 resumes
as a consequence of thethe monitored
explosion experiments and the displayed dependence with the process
of material.
parameters.
Table 2 resumes the monitored experiments and the displayed dependence with the
process parameters.

5000
-2 mm
Infrared signal intensity [u.a.]

-3 mm
4000
-4 mm

3000

2000

1000

0
0 50 100 150 200 250 300 350 400 450 500

Time [ms]

(a)

5000
6 mm
Infrared signal intensity [u.a.]

4 mm
4000
2 mm

3000

2000

1000

0
0 50 100 150 200 250 300 350 400 450 500

Time [ms]

(b)
Figure 4. Cont.
Appl. Sci. 2019, 9, x FOR PEER REVIEW 7 of 10

Appl. Sci. 2019, 9, x FOR PEER REVIEW 7 of 10

Appl. Sci. 2019, 9, 3231 7 of 10
5000
30-30 %

[u.a.] [u.a.]
40-40 %
5000
4000
50-50%
30-30 %
intensity
40-40 %
4000
3000 50-50 %
intensity
signalsignal

3000
2000

2000
Infrared

1000
Infrared

10000
0 50 100 150 200 250 300 350 400 450 500

0 Time [ms]
0 50 100 150 200 250 300 350 400 450 500

Time
(c) [ms]

(c)
5000
5000 Hz
[u.a.] [u.a.]

5000 3000 Hz
4000
1500Hz
5000 Hz
intensity

3000 Hz
4000
3000
1500 Hz
intensity
signalsignal

3000
2000

2000
Infrared

1000
Infrared

10000
0 50 100 150 200 250 300 350 400 450 500

0 Time [ms]
0 50 100 150 200 250 300 350 400 450 500

Time
(d) [ms]
Figure 4. Piercing monitored signal for stainless (d)steel 10 mm thick, varying (a) focal position; (b)
standoff; (c) duties percentage; (d) frequency. The ideal parameters are shown in black. Red and green
Figure
Figure 4. Piercing
parametersPiercing monitored
pierced the sheetsignal
monitored with for
signal stainless
for
longer steelsteel
stainless
duration. 10 mm10 thick, varying
mm thick, (a) focal
varying (a)position; (b) standoff;
focal position; (b)
(c) duties(c)
standoff; percentage; (d) frequency.
duties percentage; The ideal parameters
(d) frequency. are shown are
The ideal parameters in black.
shown Red
in and green
black. Redparameters
and green
pierced the pierced
parameters sheet with
thelonger duration.
sheet with longer duration.
5000
5,5 mm
[u.a.] [u.a.]

3,5 mm
5000
4000
2,5mm
5,5 mm
intensity

1,5mm
3,5 mm
4000
3000 2,5 mm
intensity

1,5 mm
3000
signalsignal

2000

2000
1000
VisibleVisible

10000
0 250 500 750 1000 1250

0 Time [ms]
0 250 500 750 1000 1250

Time [ms]
(a)

(a)5. Cont.
Figure
Appl. Sci. 2019, 9, x FOR PEER REVIEW 8 of 10
Appl. Sci. 2019, 9, 3231 8 of 10

5000
Visible signal intensity [u.a.] 25-25 %
22-22 %
4000
10-10 %

3000

2000

1000

0
0 250 500 750 1000 1250

Time [ms]

(b)
Figure
Figure 5.
5. Piercing
Piercing monitored
monitored signal
signal for
for aluminum
aluminum 10 10 mm
mm thick,
thick, varying
varying (a)
(a) focal
focal position;
position; (b)
(b) duties
duties
percentage. Focalpositions
percentage. Focal positionsofof
1.51.5 or and
or 2.5 2.5 duties
and duties percentages
percentages of 25 25ofand
25222522and 22 22 explosions.
provoked provoked
explosions.
Table 2. Resume of monitored experiments and dependence of process parameters.
Table 2. Resume of monitored experiments
Type of and dependence
Spectrum of process parameters.
Material Thickness Gas Process Parameters
Piercing Monitored
Type of Spectrum
Material Thickness Gas Process Parameters
Piercing Monitored - Dependence: Gas
pressure, Ramp time,
- Dependence: Gas
Mild Steel 20 mm Oxygen Soft Visible Duty Percentage
-
pressure, Ramp time,
No dependence: Focal
Mild Steel 20 mm Oxygen Soft Visible Duty Percentage
position, Standoff
- No dependence: Focal
Stainless Steel 10 mm Nitrogen Fast Infrared
No clear dependence
position, Standoff
Aluminium 10 mm Oxygen Fast Visible
Stainless
10 mm Nitrogen Fast Infrared
Steel
3.3. Optimization of Piercing Strategy No clear dependence
Aluminium 10 mm Oxygen Fast Visible
Based on the parameter dependencies observed during the monitoring of the piercing process,
it was possible toofoptimize
3.3. Optimization the strategy used in soft piercings. For mild steel 20 mm thick, firstly, a
Piercing Strategy
piercing programmed in three individual steps was used (Piercing A), each one with its own values
Based on the parameter dependencies observed during the monitoring of the piercing process,
of time, focal position, standoff, duties, and ramp time. The total piercing duration was 11–11.5 s.
it was possible to optimize the strategy used in soft piercings. For mild steel 20 mm thick, firstly, a
However, thanks to the information released from the monitoring, it was possible to select a single
piercing programmed in three individual steps was used (Piercing A), each one with its own values
piercing (Piercing B) with continuous movement between two standoffs and with two combinations of
of time, focal position, standoff, duties, and ramp time. The total piercing duration was 11–11.5 s.
duties and ramp time. This optimization was carried out through a design of experiments in which
However, thanks to the information released from the monitoring, it was possible to select a single
each process parameter was fixed and its monitoring signal analyzed in order to adjust each parameter
piercing (Piercing B) with continuous movement between two standoffs and with two combinations
for a better response in relation to time. Piercing A was based on the modification of the focal position
of duties and ramp time. This optimization was carried out through a design of experiments in which
maintaining the standoff. However, the know-how obtained in this study revealed that the piercing
each process parameter was fixed and its monitoring signal analyzed in order to adjust each
was affected by pressure, duties, and ramp time modifications. Thus, Piercing B was proposed taking
parameter for a better response in relation to time. Piercing A was based on the modification of the
into account these results. Pressure stabilization in laser cutting is not an immediate process, so this
focal position maintaining the standoff. However, the know-how obtained in this study revealed that
parameter was not directly modified. Piercing B duration showed a decrease when the focal position
the piercing was affected by pressure, duties, and ramp time modifications. Thus, Piercing B was
was fixed and the standoff was varied. This movement implied the approach of the cutting head to the
proposed taking into account these results. Pressure stabilization in laser cutting is not an immediate
sheet, improving the arrival of the gas to the piercing zone, and contributing to evacuate the material.
process, so this parameter was not directly modified. Piercing B duration showed a decrease when
Regarding duties and ramp time, the maximum values of duty minimum and duty maximum were
the focal position was fixed and the standoff was varied. This movement implied the approach of the
selected without provoking explosion, and the ramp time was also minimized. Figure 6 shows that
cutting head to the sheet, improving the arrival of the gas to the piercing zone, and contributing to
the final piercing duration was decreased to 8–8.6 s, obtaining a reduction in time of 25%. Table 3
evacuate the material. Regarding duties and ramp time, the maximum values of duty minimum and
summarizes piercing parameters values for each strategy.
duty maximum were selected without provoking explosion, and the ramp time was also minimized.
Figure 6 shows that the final piercing duration was decreased to 8–8.6 s, obtaining a reduction in time
of 25%. Table 3 summarizes piercing parameters values for each strategy.
 Appl.
Appl. Sci.Sci. 2019,
2019, 9, x FOR PEER REVIEW
9, 3231 9 of9 10
of 10

Table 3. Piercing parameters for mild steel 20 mm thick, for two different piercing strategies. Piercing
Table 3. Piercing
A was parameters
programmed for mild
as three steel 20 mm
independent thick,and
piercings for two different
piercing B aspiercing strategies.
a continuous Piercing
descendent
A was programmed
piercing process. as three independent piercings and piercing B as a continuous descendent
piercing process.
Piercing Parameters Piercing A Piercing B
Gas type
Piercing Parameters OPiercing
2 O2 A O2 O2 OPiercing
2 B
Gas type
Power [W] O2
5000 O5000 5000 O2
5000 5000
O2 O2
2
PowerPiercing
[W] time [ms]
5000 7000 50007000 3000
5000 17000
5000 5000
Gas [ms]
Piercing time pressure [bar]
7000 3 70003 33000 3 3 17000
Gas pressure Focal
[bar] [mm] 3 −3 3 −5 −7 3 −3 3−3 3
FocalInitial
[mm] standoff [mm] −3 8 −58 8 −7 8 −38 −3
Initial standoff
Final[mm]
standoff [mm]8 8 88 88 3 83 8
Final standoff [mm] 8 8 8 3 3
Frequency [Hz] 500 500 500 500 500
Frequency [Hz] 500 500 500 500 500
Duty minimum [%]8
Duty minimum [%]
8 14
14 2020 14 14
16 16
Duty maximummaximum
Duty [%] [%]
14 14 2020 2020 16 1620 20
Ramp time Ramp
[ms] time [ms]1000 1000 10001000 1000
1000 500 500 500 500

1000
Visible signal intensity [u.a.]

800

600

400

200
Piercing A
Piercing B
0
0 2000 4000 6000 8000 10000 12000

Time [ms]

Figure 6. Piercing monitored signal for mild steel 20 mm thick, varying piercing strategy.
Figure 6. Piercing monitored signal for mild steel 20 mm thick, varying piercing strategy.
4. Conclusions
4. Conclusions
We reported on a study based on the analysis of the influence of the process parameters in
We reported
laser piercing on a study
to create based on
know-how in the analysis
a field of the influence
in which commercial of the processdetect
devices parameters
the end in laser
of the
piercing to create know-how in a field in which commercial devices detect
piercing only improve piercing strategy based on laser power modifications, without considering the end of the piercing
only
other improve
process piercing strategy
parameters. based system
A monitoring on laser power modifications,
provided with a sandwich without considering
of Si-diode (400–1000othernm)
process parameters. A monitoring system provided with a sandwich of Si-diode (400–1000 nm) and
and InGaAs-diode (1000–1800 nm) that simultaneously captured the visible and infrared spectrum
InGaAs-diode (1000–1800 nm) that simultaneously captured the visible and infrared spectrum was
was used as a tool to evaluate and relate intensity signal changes to piercing process parameters
used as a tool to evaluate and relate intensity signal changes to piercing process parameters for mild
for mild steel, stainless steel, and aluminum thick sheets. The selection of the monitored spectrum,
steel, stainless steel, and aluminum thick sheets. The selection of the monitored spectrum, visible or
visible or infrared, was done based on the gas used during the experiments, oxygen or nitrogen,
infrared, was done based on the gas used during the experiments, oxygen or nitrogen, respectively.
respectively. The visible spectrum was associated with vapor plume detection and infrared spectrum
The visible spectrum was associated with vapor plume detection and infrared spectrum with
with temperature.
temperature. Soft
Soft piercing
piercing was was required
required forfor mild
mild steel
steel 2020mmmm thick,observing
thick, observing visible
visible monitored
monitored
signal dependence
signal dependence withwithpressure,
pressure, andandduties
dutiespercentage
percentageand andramp
ramptime,
time,parameters
parametersdirectly
directly related
related to
thetomaterial ejection or to the formation of vapor plume by modifications in
the material ejection or to the formation of vapor plume by modifications in laser power, laser power, respectively.
Based on these results,
respectively. Based onthethese
piercing timethe
results, duration wastime
piercing reduced by 25%.
duration wasFor stainless
reduced steel and
by 25%. For aluminum
stainless
10 mm
steelthick, fast piercing
and aluminum was thick,
10 mm used. fast
In the first case,
piercing wasinfrared
used. Insignal intensity
the first displayed
case, infrared a lower
signal signal
intensity
intensity in ideal
displayed piercing
a lower signalconditions
intensity inthan
idealinpiercing
non-ideal ones duethan
conditions to having a minimum
in non-ideal ones due heating in the
to having
piercing zone. Regarding aluminum, the visible signal was saturated when
a minimum heating in the piercing zone. Regarding aluminum, the visible signal was saturated when an explosion occurred,
as an explosion occurred,
a consequence as a ejection
of material consequence of material
and vapor plume ejection and vapor
saturation. Theseplume
resultssaturation.
showed that Thesethe
results showed
optimization of thethat the optimization
piercing time for soft ofpiercings
the piercing
wastime for soft
feasible piercings
thanks to thewas feasible thanks
knowledge obtained to the
from
knowledge obtained from the monitoring inputs. For fast piercings exists also the
the monitoring inputs. For fast piercings exists also the possibility of establishing a threshold to control possibility of
the piercing results. This paper shows the potential of the process monitorization, not only to detect the
final stage of the piercing, but also to create knowledge that can optimize the actual piercing strategies.
Appl. Sci. 2019, 9, 3231 10 of 10

Author Contributions: Conceptualization, S.M.G. and J.F.; methodology, S.M.G.; investigation, J.R. and S.M.G.;
validation, J.R. and S.M.G.; formal analysis, S.M.G, A.L., and J.F.; resources, J.F.; writing—original draft preparation,
S.M.G.; writing—review and editing, S.M.G, A.L., and J.F.
Funding: This research received no external funding.
Conflicts of Interest: The authors declare no conflict of interest.

References
1. Poprawe, R. Modeling, monitoring and control in high quality laser cutting. CIRP Ann. 2001, 50, 137–140.
[CrossRef]
2. Hashemzadeh, M.; Powell, J.; Voisey, K.T. Fibre laser piercing of mild steel—The effects of power intensity,
gas type and pressure. Opt. Lasers Eng. 2014, 55, 143–149. [CrossRef]
3. Wen, P.; Zhang, Y.; Chen, W. Quality detection and control during laser cutting progress with coaxial visual
monitoring. J. Laser Appl. 2012, 24, 032006. [CrossRef]
4. Schuöcker, D.; Schuöcker, G. Dynamic phenomena and quality defects in laser cutting. In Proceedings of
the International Symposium on High Power Laser Ablation 2012 AIP Conference, Santa Fe, NM, USA,
30 April–3 May 2012.
5. Kaebernick, H.; Jeromin, A.; Mathew, P. Adaptive control for laser cutting using striation frequency analysis.
Ann. CIRP 1998, 47, 137–140. [CrossRef]
6. Sobih, M.; Crouse, P.L.; Li, L. Elimination of striation in laser cutting of mild steel. J. Phys. D Appl. Phys.
2007, 40, 6908–6916. [CrossRef]
7. Wee, L.M.; Li, L. An analytical model for striation formation in laser cutting. Appl. Surf. Sci. 2005, 247,
277–284. [CrossRef]
8. Schleier, M.; Adelmann, B.; Esen, C.; Hellmann, R. Cross-correlation based algorithm for monitoring laser
cutting with high power fiber lasers. IEEE Sens. J. 2017, 18, 1585–1590. [CrossRef]
9. Adelmann, B.; Schleier, M.; Neumeier, B.; Hellmann, R. Photodiode-based cutting interruption sensor for
near-infrared lasers. Appl. Opt. 2016, 55, 1772–1778. [CrossRef] [PubMed]
10. Adelmann, B.; Schleier, M.; Neumeier, B.; Wilmann, E.; Hellmann, R. Optical cutting interruption sensor for
fiber lasers. Appl. Sci. 2015, 5, 544–554. [CrossRef]
11. Rao, B.T.; Ittoop, M.O.; Kukreja, L.M. A power ramped pulsed mode laser piercing technique for improved
CO2 laser profile cutting. Opt. Lasers Eng. 2009, 47, 1108–1116.
12. Pocorni, J.; Powell, J.; Frostevarg, J.; Kaplan, A.F.H. Investigation of the piercing process in laser cutting of
stainless steel. J. Laser Appl. 2017, 29, 022201. [CrossRef]
13. De Keuster, J.; Duflou, J.R.; Kruth, J.P. Monitoring of high-power CO2 laser cutting by means of an acoustic
microphone and photodiodes. Int. J. Adv. Manuf. Technol. 2017, 35, 115–126. [CrossRef]
14. Kek, T.; Grum, J. Monitoring laser cut quality using acoustic emission. Int. J. Mach. Tool 2009, 49, 8–12.
[CrossRef]
15. Active Piercing. Available online: http://demo.blmgroup.com/en/innovation/innovative-solutions/activetools-
fast-oxygen-piercing.aspx (accessed on 7 August 2019).
16. Pierce Line. Available online: https://www.trumpf.com/filestorage/TRUMPF_Master/Products/Services/01_
brochures/TRUMPF-product-enhancements-catalog-DE.pdf (accessed on 7 August 2019).
17. Regulated Pulse Pierce (RPP). Available online: https://www.lmclaser.com.au/rpp-regulated-pulsed-piercing/
(accessed on 7 August 2019).
18. Available online: https://www.balliu.be/products/laser-cutting/features/lpm-piercing-control/ (accessed on
7 August 2019).
19. Available online: http://www.eckert-saga.com/en/maquinas/diamond-fiber-laser-2/#accessories (accessed on
7 August 2019).
20. Available online: https://www.spilasers.com/wp-content/uploads/2017/11/Fiber-laser-piercing-enhances-
cutting-productivity.pdf (accessed on 7 August 2019).

© 2019 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access
article distributed under the terms and conditions of the Creative Commons Attribution
(CC BY) license (http://creativecommons.org/licenses/by/4.0/).