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Optics and Laser Technology 93 (2017) 67–73

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Optics and Laser Technology


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Full length article

Laser cutting of various materials: Kerf width size analysis and life cycle
assessment of cutting process
Bekir Sami Yilbas ⇑, Mian Mobeen Shaukat, Farhan Ashraf
Mechanical Engineering Department, KFUPM, Box 1913, Dhahran 31261, Saudi Arabia

a r t i c l e i n f o a b s t r a c t

Article history: Laser cutting of various materials including Ti-6Al-4V alloy, steel 304, Inconel 625, and alumina is carried
Received 18 December 2016 out to assess the kerf width size variation along the cut section. The life cycle assessment is carried out to
Received in revised form 21 January 2017 determine the environmental impact of the laser cutting in terms of the material waste during the cutting
Accepted 14 February 2017
process. The kerf width size is formulated and predicted using the lump parameter analysis and it is mea-
Available online 23 February 2017
sured from the experiments. The influence of laser output power and laser cutting speed on the kerf
width size variation is analyzed using the analytical tools including scanning electron and optical micro-
Keywords:
scopes. In the experiments, high pressure nitrogen assisting gas is used to prevent oxidation reactions in
Laser cutting
Kerf width size
the cutting section. It is found that the kerf width size predicted from the lump parameter analysis agrees
Life cycle assessment well with the experimental data. The kerf width size variation increases with increasing laser output
power. However, this behavior reverses with increasing laser cutting speed. The life cycle assessment
reveals that material selection for laser cutting is critical for the environmental protection point of view.
Inconel 625 contributes the most to the environmental damages; however, recycling of the waste of the
laser cutting reduces this contribution.
Ó 2017 Elsevier Ltd. All rights reserved.

1. Introduction power in the cutting section. Since the efficiency of the lasing
devices is low, which in the order of 30% [2], the electrical energy
Laser cutting of sheet metals offers significant advantages over consumption increases the cost of machining and contributes to
the conventional cutting methods; some of these include precision the environmental degradation. This is due to the electrical energy
of operation, high speed processing, and low cost. Laser cutting generation from turbines, particularly gas and steam turbines,
involves with high temperature processing of materials including which have adverse effect on the environment. Consequently,
solid phase heating, melting, and evaporation. In the case of metal- investigation of the laser cutting process from the environmental
lic materials processing, assisting gas is used to reduce the oxida- perspective via life cycle assessment becomes essential.
tion reactions in the cutting section. Since the oxidation reactions Laser cutting process and the assessment of cutting parameters
gives rise to excessive heating in the cutting section via high tem- on kerf size and geometry are important aspects of the quality
perature exothermic reactions, the resulting section suffers from evaluation of the end product. Optimization studies on laser cut-
cutting asperities such as sideways burning, dross attachments, ting offers improved process control and securing of the end pro-
and thermal erosion [1]. The proper controlling of the laser cutting duct quality. Modelling and optimization study for the
process through appropriate selection of the cutting parameters assessment of the cut quality of a thin aluminum-alloy was carried
minimizes the defect sites along the cut sections. However, further out by Sharma and Yadava [3]. They introduced the entropy mea-
investigations are needed for net shaping of the materials, which surement methodology for the calculation of weight corresponding
involve with high thermal conductivities and low fracture tough- to each quality characteristic. They indicated that the hybrid
ness such as titanium alloys and alumina. On the other hand, a care approaches for modelling and optimization of the laser cutting
must be taken during the cutting process from the perspective of process provided reasonably good accuracy. Optimization of multi-
the energy consumption. This is because of the fact that a laser ple quality characteristics in laser cutting of titanium alloy sheet
as a machine tool uses the electrical energy to generate irradiated was examined by Pandey and Dubey [4]. They identified important
control factors related to the quality characteristics for kerf taper-
ing and surface roughness. Jet impingement onto a laser produced
⇑ Corresponding author. kerf and the effect of kerf wedge angle on heat transfer rates and
E-mail address: bsyilbas@kfupm.edu.sa (B.S. Yilbas).

http://dx.doi.org/10.1016/j.optlastec.2017.02.014
0030-3992/Ó 2017 Elsevier Ltd. All rights reserved.
68 B.S. Yilbas et al. / Optics and Laser Technology 93 (2017) 67–73

skin friction were investigated by Melhem et al. [5]. They demon- for die manufacturing were investigated by Morrow et al. [15].
strated that the kerf wall wedge angle had considerable influence They indicated that laser-based remanufacturing of tooling could
on the Nusselt number and the skin friction. Laser cutting of the reduce the processing cost and environmental impact simultane-
triangular geometries in aluminum foam and the influence of cut ously, especially as the scale of the tool increased.
size on thermal stress levels were studied by Yilbas et al. [6]. The Laser machining process and life cycle assessment was pre-
findings revealed that small size triangle cuts resulted in relatively sented earlier [13], the main focus was to use laser deposition tech-
higher temperatures around the cut edges as compared to large nique to produce parts and the life cycle assessment for the laser
size triangle cuts; however, opposite was true for von Mises stress cutting of different materials was left for the future study. In the
levels. This was attributed to the slow cooling rates in the case of present study, laser gas assisted cutting of titanium alloy, steel, alu-
the small size triangle cuts. On the other hand, considerable mina, and Inconel alloy was carried out. The effect of laser output
research studies were carried out to examine the laser machining power and cutting speed on the resulting cut geometries, in terms
process and environmental impact. Energy related life cycle impact of the kerf width size variation, is studied. The life cycle assessment
and cost reduction opportunity in laser cutting process was studied of the laser gas assisted cutting process was carried out to examine
by Devoldere et al. [7]. They showed that the CO2 laser source and the environmental impact of the laser cutting process.
the chiller unit were the largest energy consumers during the pro-
cessing time. In addition, during non-productive time, 12% of the 2. Experimental
yearly energy consumption was required to keep the chiller and
other components active. Environmental assessment of laser A CO2 laser (LC-ALPHAIII) delivering nominal output power of
assisted manufacturing incorporating the laser shock peening 2000 kW was used to irradiate the workpiece surface. The laser
and laser assisted turning was carried out by Zhao et al. [8]. They output intensity was in the form of high frequency repetitive
indicated that the environmental performance of the two laser pulses having the frequency of 1500 pulses per second. The wave-
based processes was significantly better than those of the conven- length of the laser is 10.6 µm and laser output intensity is Gaussian
tional processes. For the laser shock peening of aluminum, the with TEM00 mode. The nominal focal length of the focusing lens
analysis indicated that this was mainly due to the significant was 127 mm and the laser beam diameter focused at the work-
extension of fatigue life of the workpiece being treated. For the piece surface was 0.25 mm. Nitrogen assisting gas at high pressure
laser assisted turning of compacted graphite iron, the improved was introduced coaxially with the laser beam through a nozzle. A
performance was mainly due to the extended tool life since cutting computer controlled x, y table was used to mount the workpieces
tool manufacturing was an energy intensive process. In addition, of 2 mm thickness. The laser power intensity was varied in
development of high-power laser with a lower wavelength (e.g. between 500 and 1500 W while the x, y table speed was changed
direct diode system) could eliminate the use of paint in laser within 5–10 cm/s in the experiment. Nitrogen gas pressure was
assisted turning. Energy efficiency assessment of laser drilling pro- kept at 550 kPa during the experiments. Table 1 gives the laser cut-
cess was investigated by Apostolos et al. [9]. They presented the ting parameters used in the experiments.
laser processing efficiency incorporating two different analyses, After completion of the cutting process, the widths of resulting
which include: (i) considering the entire laser system, and (ii) cuts were measured and SEM microphotography of the cut sur-
including only the workpiece – laser beam interactions. Optimiza- faces was carried out. To measure the striation depths and widths,
tion of cutting parameters for minimizing power consumption and the surface roughness measurement was carried out using a
maximizing tool life during machining of composites was studied Bendix stylus instrument; in which case, the difference of kerf
by Bhushan [10]. He showed that multi response optimization width size (Dwk) was obtained. The difference of kerf width size
through desirability analysis route reduced power consumption was determined from:
by13.55% and increased tool life by 22.12%. The optimization study
for the laser cutting process, incorporating the laser parameters
DwkP=S ¼ ðwkn ÞP=S  ðwknþ1 ÞP=S
with multi-performance characteristics, was carried out by Caydas wk is the kerf width size, and indices of P and S represents the kerf
and Hascalik [11]. They demonstrated that grey relational grade widths due to laser output power variation and the laser cutting
analysis provided useful information on the laser cutting process; speed, respectively. The kerf width size ratio is determined from
in which case, the laser power had more effect on the cutting qual- the following equation:
ity than that of the cutting speed. Laser-assisted machining of
Inconel 718 and the economic analysis was studied by Anderson ðwkn ÞP=S  ðwknþ1 ÞP=S
et al. [12]. They presented the machinability of Inconel 718 under %DwkP=S ¼
ðwkav erage Þ
various conditions. They demonstrated that with increasing mate-
rial removal temperature from room temperature to 620 °C, the where wkav erage is the average of the kerf width size along the cutting
benefit of laser assisted machining was demonstrated by a 25% edge.
decrease in the specific cutting energy. In this case, 2–3-fold
improvement in surface roughness and a 200–300% increase in
3. Kerf width analysis
ceramic tool life over conventional machining were reported. The
energy and environmental impact analysis of remanufacturing of
Introducing the lumped parameter technique, the overall
turbine blades via laser direct deposition was carried out by Wilson
energy balance for the laser cutting process could be simplified
et al. [13]. They demonstrated the effectiveness of laser direct
[16]. This relation can be written as [16]:
deposition in remanufacturing and its potential to adapt to a wide pffiffiffiffiffiffiffiffiffi
range of part defects. A Life Cycle Assessment (LCA) on the energy P v wk þ A3 v wk
¼ ð2Þ
and environmental impacts by remanufacturing was also pre- d Ao
sented. Energy and resource efficiency of laser cutting processes
where
was examined by Kellens et al. [14]. They provided an overview
of the environmental performance in terms of energy. In addition, A 1 ðwk þ 2wkðTm To ÞÞ
Ao ¼ ; A3 ¼ pffiffiffiffiffiffiffiffiffiffiffiffiffiffi and
they derived the resource efficiencies of different types of laser cut- ao ao 2 awwk
ting systems and demonstrated the performance improving strate- aa ¼ q½CpðTm  To Þ þ Lm þ bLb 
gies. Environmental aspects of laser-based and conventional tool
B.S. Yilbas et al. / Optics and Laser Technology 93 (2017) 67–73 69

Table 1
Laser cutting conditions used in the experiment.

Scanning Speed (m/s) Power (W) Frequency (Hz) Nozzle gap (mm) Nozzle diameter (mm) Focus setting (mm) N2 pressure (kPa)
0.05–0.1 300–1500 1500 1.5 1.5 127 550

The term ‘‘Ao” is related to energy transfer rate to the workpiece Table 3
at the surface during laser-workpiece interaction. ‘‘A” is the effec- LCA inventory data for Laser Cutting Process.

tive energy coupling factor at the workpiece surface, and ‘‘A3” is Materials Gas consumption Energy consumption Amount of waste
related to energy loss due to conduction in the solid. b is the frac- (kg) (J) (kg)
tion of evaporation contribution at the workpiece surface. Ti-6Al-4V 1.0833 5.10E+03 1.42E02
Using the scale law, the kerf width can be written in a simplified Steel 0.7222 2.33E+03 3.14E+01
form as [16]: Al2O3 1.0833 1.30E+04 1.59E+01
Inconel 0.7222 3.65E+03 3.38E+01
h pffiffiffi pffiffiffiffii
gu
P v
625
1 2:51 wa kðT2A
m T o Þ
wk ¼   ð3Þ
v 1 þ 3:08  108 Ap
o ffi
qqg r2 a
pffiffiffi P
pffiffiffiffi
v
A3 f M w Pg f w

Inconel 625 were gathered. The data was collected for energy con-
where ‘‘f” is the fraction of the pressure drop in the kerf, r is the
sumption, shielding gas consumption, and waste produced during
molecular diameter (Angstrom unit), Mw is the molecular weight
laser cutting. The data is summarized in Table 3.
(g/mol unit) of the assisting gas, Pg and qg are the pressure and den-
After data collection, SimaPro is used as the software to build
sity of the assisting gas, and gu is the superheating factor in the melt
the LCA model and calculate environmental impact. There are
pool.
various methods that can be used for impact assessment. For this
Eq. (3) is used to determine the kerf width while energy cou-
study, CML was used. This assessment tool is named after the
pling factor (A), laser power (P), and cutting speed (v) are consid-
research institute (Center of Environmental Science of Leiden
ered as variables in Eq. (3). The material properties used in the
University) and was developed by a group of scientists under the
computations are given in Table 2.
lead of center of environmental science of Leiden University. The
CML method is based on the problem oriented approach and it
4. Life cycle assessment (LCA) calculates various categories of environmental impact including
Global warming potential, Eutrophication potential, Human toxic-
Sustainable manufacturing has gained significant importance in ity potential, Ozone layer depletion potential, Acidification poten-
industry. There is urgent need to reduce the environmental impact tial, and Abiotic depletion factor, etc. [20].
in all stages of product design and manufacturing. Life Cycle
Assessment (LCA) is a widely used technique to evaluate environ- 5. Results and discussion
mental impact of manufacturing processes. LCA is an ISO-
standardized method used to evaluate environmental impact from Laser gas assisted cutting of titanium alloy (Ti-6Al-4V), steel
a cradle-to-grave perspective [17,18]. Several researchers have 304, alumina, and Inconel 625 superalloy was carried out. The
used this technique to measure environmental impacts of manu- effect of laser output power and cutting speed on the percentage
facturing processes and to compare novel manufacturing tech- of kerf width size variation is analyzed. The life cycle assessment
niques with conventional manufacturing techniques [18,19]. of the laser cutting process is also presented.
ISO standard lists four steps for performing LCA: goal and scope Figs. 1 and 2 show SEM micrographs of laser cut kerf surfaces of
definition, life cycle inventory analysis, life cycle impact assess- the workpieces for two laser output power settings and two cut-
ment, and interpretation. The first step of analysis is to define goal ting speeds. The kerf surfaces appear to be almost similar for
of study which includes the purpose and intended application of metallic materials; in which case, some striations with flow of liq-
study. The goal for current study is to investigate and compare uid metal are observed. The rapid solidification of the liquid metal
environmental impacts of laser cutting of four different materials. at the surface, due to the convection cooling effect of the high pres-
In order to compare various processes in LCA a functional unit sure assisting gas, gives rise to the formation of the cast layer at the
(quantification of useful service provide by the process) must be
kerf surface. This situation is observed for the low cutting speeds
defined. The data was collected for cutting 1 m long and 4 mm (Fig. 1a–d) or high laser power intensities (Fig. 2a–d). Because of
thick plate, hence laser cutting of 1 m long and 4 mm thick plate
the high temperature gradients formed in the cast layer, thermal
is considered as a functional unit for this study. strain remains high in this region. This, in turn, gives rise to forma-
In second phase of LCA, Life Cycle Inventory Analysis, data of
tion of micro-cracks at the kerf surface, which are seen on the kerf
laser cutting of four materials Ti-6Al-4V, Steel 304, Al2O3 and surfaces. In the case of high power or low speed cutting process,
the cracks are partially extended on the kerf surface unlike the
low power and high speed cutting process. This behavior is attrib-
Table 2
uted to the thickness of the melt (cast) layer, which increases with
Assisting gas properties and data used in the simulations. the laser output power or the low cutting speeds. Therefore, the
cooling rates at the surface region of the cast layer are modified
Source of variation Value Units
by the bulk of heated layer below the surface. Consequently, heat
Density of assisting gas 1.25 kg/m3 conduction from the cast layer towards to surface region modifies
Fraction of evaporation contribution (b) 0.1 –
Fraction of pressure drop (f) 0.1 –
the cooling rates and the temperature gradient in the surface vicin-
Energy coupling factor (A) 0.5 – ity of the cast layer reduces. Hence, formation of the crack network
Super heating factor in the melt front (gu) 0.02 – is suppressed with the relatively lower cooling rates as compared
Molecular diameter of nitrogen 3.64 Å to those corresponding to the cutting conditions with high cutting
Superheating factor 0.02 –
speeds or low laser output power. It should be noted that in high
70 B.S. Yilbas et al. / Optics and Laser Technology 93 (2017) 67–73

Fig. 1. SEM micrographs of laser cut kerf surfaces: (a) stainless steel, (b) Inconel 625, (c) Ti-6Al-4V alloy, and (d) alumina. The laser power is 1500 W and the cutting speed is
0.07 m/s.

Fig. 2. SEM micrographs of laser cut kerf surfaces: (a) stainless steel, (b) Inconel 625, (c) Ti-6Al-4V alloy, and (d) alumina. The laser cutting speed is 0.05 m/s and laser power
is 800 W.

speed or low power cutting, the cast layer formed at the kerf sur- results in sideways burning and deep molten layer formation at
face remains thin while resulting in attainment of high tempera- the kerf surface. It should be noted that high temperature exother-
ture gradients. This situation results in the crack network mic reactions results in excessive energy generation contributing
formation on the kerf surface. Moreover, in the case of titanium to the laser beam energy in the cutting section [21]. This causes
alloy, the striation depth remains large at the kerf surface. This is deep striation patterns at the surface [22]. In the case of alumina
associated with the high oxidation potential of titanium, which cutting, the kerf surface demonstrates the striation patterns; how-
B.S. Yilbas et al. / Optics and Laser Technology 93 (2017) 67–73 71

Fig. 3. Percentage of kerf width size variation with the laser output power for various materials. The laser cutting speed is kept constant at 0.07 m/s in the experiment and in
the predictions.

Fig. 4. Percentage of kerf width size variation with the laser cutting speed for various materials. The laser output power is kept constant at 1000 W in the experiment and in
the predictions.

ever, the depth of the striation patterns appears to be shallow as width size variation (Dwk-P) increases with increasing output beam
compared to those corresponding to the titanium alloy. In addition, power. In the case of other metallic materials, increasing laser out-
few surface cracks are observed in the cast layer, which is related put power causes increase of the kerf width size variation (Dwk-P).
to the formation of high thermal strain under the high temperature This situation is due to the increased in the kerf width size with
gradients in this region. increasing laser output power. Therefore, the kerf width size insta-
Figs. 3 and 4 show the variation of the percentage of kerf width bility occurs while giving rise to attainment of large Dwk-P. In the
size in terms of the kerf width difference with laser output power case of the laser cutting speed (Fig. 5), the percentage of kerf width
(Dwk-P) and with laser cutting speed (Dwk-S) for different materials. size variation (Dwk-S) demonstrates the opposite behavior to that
It should be noted that the cutting speed is kept constant at 0.1 m/s for the laser output power (Fig. 4). In this case, increasing laser cut-
in Fig. 3. Increasing laser output power increases the percentage of ting speed lowers the kerf width while reducing the percentage of
percentage kerf width size. In addition, the kerf width difference kerf width size variation along the cut edges. However, the percent-
(Dwk-P) increases with increasing laser output power, which is more age of kerf width size variation (Dwk-S) reduces significantly at high
pronounced for the titanium alloy. This is because of the high tem- cutting speeds as compared to those other materials considered.
perature exothermic reactions, which provide excess energy in the This is, again, associated with the formation of large molten layer
cutting section. Since the assisting gas used is nitrogen, the presence due to the excessive energy provided via ectothermic reactions in
of the oxygen remains low in the cutting section. However, high oxy- the cut section, i.e. kerf size variation becomes large for the low cut-
gen affinity of titanium alloy gives rise to the oxidation reactions ting speeds because of the high residence time of the laser beam in
taking place locally in the cutting section. Therefore, localized ther- the cutting section. In the case of alumina, the percentage of kerf
mal erosion is resulted at the kerf surface while causing the deep width size variation (Dwk-P and Dwk-S) remains low, which is due
striation formations. In addition, this gives rise to the formation of to smaller variation in the percentage of kerf width size as compared
varying kerf width size along the cut edges. Consequently, kerf to those of the metallic materials.
72 B.S. Yilbas et al. / Optics and Laser Technology 93 (2017) 67–73

Fig. 5. Impact assessment results for laser cutting process of different materials.

On the other hand, in life cycle assessment, six impact cate- equivalents per kg emission. AP described the rate of deposition
gories are considered. These include Global Warming Potential of acidifying substance. AP is expressed as kg SO2 equivalents
(GWP), Abiotic Depletion Factor (ADF), Ozone Depletion Poten- per kg emission. EP includes all impact due to macro nutrients
tial (ODP), Photochemical Ozone Creation Potential (POCP), Acid- in the environment caused by the emission of nutrients to air,
ification Potential (AP), and Eutrophication Potential (EP). In this water and soil. It is expressed as kg PO4 equivalents per kg
case, GWP is related to emission of greenhouse gases and it is emission. The results of study from life cycle impact assessment
defined for time horizon of 100 years in kg CO2 per kg emission. are interpreted next.
ADF is related to extraction of materials and is measured in kg The environmental impacts GWP, ADF, ODP, POCP, AP and EP
antimony equivalents per kg extraction. ODP is a measure of contributed from laser cutting of four different materials as shown
stratospheric ozone depletion. Its unit is kg CFC-11 equivalents in Fig. 5. The results show that laser cutting of Inconel 625 is more
per kg emission. POCP is concerned with the formation of reac- damaging to environment as compared to laser cutting of other
tive substances (mainly ozone) in the atmosphere which are three materials. Also Ti-6Al-V has the least impact on environment
injurious to human health. POCP is expressed as kg ethylene during laser cutting. To estimate impacts due to different inputs of
B.S. Yilbas et al. / Optics and Laser Technology 93 (2017) 67–73 73

laser cutting process, environmental burdens due to energy, gas, Acknowledgements


and waste materials were also calculated. First thing to note from
Fig. 5 is that energy accounts for nearly negligible share of the The authors acknowledge the support of King Fahd University
environmental impact for all the materials. Next the contribution of Petroleum and Minerals Dhahran Saudi Arabia.
of shielding gas is more than energy consumption however it is
far less than the damage caused by the waste material generated References
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laser waste materials, such as ejected dross from the kerf sites,
can be mitigated by recycling the waste materials.

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