JOURNAL OF LASER APPLICATIONS. VOLUME 18, NUMBER 2 CO, laser beam-cutting of steels: Material issues Murali Manohar® Mittal Steel USA R&D, East Chicago, Indiana 46312 (Received 8 March 2005; accepted for publication 7 November 2005) Laser beam cutting and its advantages along with its relevance to worldwide trends in manufacturing are introduced, Results of efforts to identify material-telated factors that render steel suitable for laser cutting are described. Key material requirements for both hot-strip and discrete plate products have been summarized using data collected over several years based on anecdotal information as well as experimental results, It has become clear that near-zero residual stresses and minimum level of residual elements (Cu, Ni, and Cr) are necessary to obtain clean pierces and consistent cut quality in thick (20~25 mm) plates, in both as-rolled and as-shot-blasted conditions using conventional CO; laser cutting, A mechanism to explain why the presence of residual elements results in improved cut quality is proposed. Further work required to develop a better understanding of laser cutting has been highlighted and recent process developments that could signifieaintly impact this technology have been outlined. © 2006 Laser Institute of America. Key words: laser beam cutting, steels, residual elements, CO, laser, residual stresses, surface scale MAY 2006 1 INTRODUCTION AND BACKGROUND Since its development in the 1960s, the CO, laser has been used for a wide variety of materials processing appli- cations such as welding, cutting, driling, marking, heat treat- ment, and surface modification.' By the early 1990s it was established thatthe largest single use of CO» lasers in mate- rials processing was in cutting and related processes such as dcilling, trimming, and scribing® and that mild steel was the most commonly cut material.” The American Welding Soci ety describes laser beam cutting (LBC) as “a thermal cutting [process that severs material by locally melting or vaporizing with the heat from a laser beam."® Metals can be laser cut with or without an oxidizing assist gas (laser oxidation cut- ting and laser fusion cutting, respectively) to remove the ‘molten and vaporized material. In the case of carbon and low alloy steels, a jet of oxygen coaxial with the laser beam is ‘commonly used as the assist gas. In leser oxidation cutting: ‘+ Energy from the exothermic reaction of iron with oxygen significantly contributes to the cutting action. * Oxygen renders the molten droplets less adhesive, and therefore, easier to remove from the edge, * The oxide on the melt surface improves energy coupling, and therefore, process efficiency, With available laser power levels of 1500 W or less up to the early 1990s, the use of LBC was limited to a steel thickness of about 6 mm (1/4 in.) while plasma arc cutting (PAC) and oxyfuel cutting (OFC) were used for cutting thicker sections, Despite the higher equipment cost and the greater need for operator training compared to OFC and PAC, laser cutting looked attractive to fabricators, since it offered the following advantages relative to other thermal ‘and mechanical cutting methods: electronic mail: mural manoharG@mitalsteel com 1042-346K/2006/18(2)/101/12/828.00 101 « less edge rounding; + Tess dross; + narrow kerf/heat-affected zone; «+ higher material yield/less scrap; « less distortion; « better dimensional accuracy (enabling more consistent ‘weld fit-up for process automation and product durability); + smoother cut appearance; ® noncontact process, i.e., no tool wear; ' less fumes and radiation; and © opportunity to consolidate several operations (@.g., blank- ing, nibbling, punching, and drilling). However, high productivity was. not achievable with thicker sections, since lasers capable of simultaneously de- livering higher power levels and good beam mode were not readily available until recently. Therefore, laser cutting was limited to steel thicknesses of about 6 mm or less. After in- ‘vesting in considerable developmental efforts in laser cavity design and laser optics materials, laser manufectarers are now able to achieve better and more stable beam modes with higher laser powers. For instance, Ross® reported in 1992 that Gaussian modes were achieved with a 4 kW laser. This, ‘meant that smaller focused spot sizes and larger depth of focus were attainable and that thicker sections could be cut with laser beams. Ketting and Olsen” demonstrated that at a given power level, higher cutting speeds could be achieved with smaller focused spot sizes. Starting in the mid-1990s, there has been a rapid in- crease in the use of laser cutting in manufacturing industries such as construction, heavy machinery, shipbuilding, agricul- ture, and mining. It was recognized that the reduced distor- tion and improved dimensional accuracy achievable with la- ser cutting would lead to consistent weld joint fi-up, and therefore, more durable structures. The tighter control over ‘© 2006 Laser Insitute of America102 J. Laser Appl. Vol. 18, No. 2, May 2006 ‘weld joint fit-up and the resulting dimensional accuracy also enabled greater process automation and use of robotics for welding and other operations to improve productivity. While ‘Cutting up to 16 mm thick steel plate using a 6 KW CO, laser was considered a significant achievement in 1992,"° fabrica- tors currently make routine production cuts on 25 mm thick steel plates using 6 kW lasers, and are looking to cut even thicker sections, ‘A. Worldwide development of steels for laser cutting European manufacturers appear to have taken the lead in efforts to use LBC, and steel producers in Europe responded to the demand by first developing sheet grades suitable for laser cutting, Sollac (now part of Arcelor) was reportedly the first to actually market such a product—“Sollaser"—in the carly 1990s. Rautaruukki Steel (now Ruukki Steel) followed with “RAEX Laser” products. Thyssea Stahl developed “LC” products and Swedish Stee! reported that cut quality obtained with their popular “Domex” products was as good, or better than, the so-called “laser-cutting” products." British Steel (now part of Corus) and Sidstabl (now part of Arcelor) introduced “Lasersure” and “Sidlaser” hot-strip products, respectively. Voest Alpine introduced LASER ALFORM hot-strip products. In Japan, Chubu Kohan, an electric furnace steelmaker, developed S$ 400-LS “laser cutting” plate, and has marketed it since the early 1990s.!? Dillinger Hitte GTS introduced “DICUT,” a discrete plate product guaranteed to.give good laser cuts. As Blomquist"? reports, major Japanese shipyards installed high-power laser cutting systems. Some Japanese steel producers’ obtained patents for shipbuilding and structural steel plate products suitable for laser cutting."*"* In North America, several stee! companies, e.g., IPSCO, Nucor, Citisteel, and Mittal Stee! USA (Comprising the erstwhile International Steel Group which acquired Bethlehem Steel Corporation), currently market plate products suitable for laser cutting. A summary of steel products suitable for laser cutting marketed worldwide based on information from available marketing brochures or product literature is shown in Table I. North American fabricators started to follow the European trend and the number of laser cutting machines being installed has increased rapidly over the last few years. Since laser cutting is the first step in a high productivity, minimum rework, close tolerance manufacturing system, obtaining consistently high quality cuts has become a critical requirement. As a result, there is increasing demand for steels that produce consistently good laser cuts, Several fabricators use laser cutting extensively and are trying to extend the process to thicker sections. As Denney’ reports, there is growing use of laser cutting in the shipbuilding industry worldwide, Bender Shipbuilding installed a Tanaka ‘6 KW laser to cut up to 25 mm thick plate in the mid-1990s and also led a National Shipbuilding Research Program (NSRP)-funded consortium exploring the use of lasex.cutting for shipbuilding.’ GE Electric Boat installed a 4 kW laser cutting machine from ESAB for use in the manufacture of submarines for the US Navy,'* and Northrup Grummann Ship Systems is in the process of installing laser cutting, ‘Murali Manohar equipment in their Avondale and Pascagoula operations, ‘Trumpf, Ine., introduced 2 5 kW laser cutting machine capable of cutting over 25 mm thick plate, to the North American market, Laser cutting machines with power levels of 6 KW are also available from PRC Laser and W. A. ‘Whitney. It is clear from discussions with leading domestic laser cutting equipment manufacturers that the demand for laser cutting equipment is expected to continue to increase in the coming years, since increasingly thicker sections are being cut using lasers. B. Factors determining laser cut quality Even though there are patents! and marketing brochures on steels suitable for laser cutting from several steel producers, there is limited published information on the key material characteristics required to give consistently ‘good laser cuts. Information available in books on laser cutting! or laser materials processing” is limited to cutting thin sections, and does not address thick plate cutting, As Powell ef al." point out, with increasing material thickness at a constant laser power level, the process becomes less efficient as conductive losses increase. Since the oxygen pressure has to be kept low to minimize undesirable edge burning, the window within which good cuts can be obtained becomes narrower with increasing thickness, Cut quality is critically dependent on the dynamics of interaction of the laser beam and the oxygen jet with the steel, and is determined by three independent factors: * cutting parameters (laser type, power level, travel speed, beam mode, oxygen pressure, lens focal length, focus point, frequency, duty oyole, ete); * equipment maintenance (beam quality resulting from the condition of the machine); and © material characteristics, ‘The combination of these factors provides a window within which good quality cuts can be made. The challenge facing steel producers is to develop steels that have a wide cutting window, so that even under less-than-optimum cut- ting conditions, acceptable cuts can be produced on a con- sistent basis, . Observations on laser cut quality Based on experience gained over the last few years, the following observations can be made on material-related issues germane to laser cutt * Cut quality is very dependent on the plate or sheet surface and its consistency. + Surface scale has to be uniform, dense and tightly adherent for good cut quality, ‘+ The plate should be flat and free from residual stresses for good cut quality. + Steels containing the elements Cu, Ni, and Cr are found to ‘cut consistently better than those not containing these ele~ ‘ments in the as-rolled as well as shot-blasted conditions. * Steels containing the elements Cu, Ni, and Cr are found to consistently pierce in shorter times and with less blow- a elt olJ. Laser Appl, Vol. 18, No. 2, May 2006 Murai Manohar 103 ‘TABLE L Summary of laser cutting progucts marketed worldwide (from available marketing brochures)" “Thickness and face Chances Coopary _enndtion Profs mated (cle comments om marsting roche) Hocsp i Sauer Upto 8 am bout ; ‘USINOR Group HR or HRPO DIZ “S<000e ne ee p12 + Rede lvl of intra sete, ‘vow pe sus «Tighter oeraces on dmecson tod ‘Soldur 355, amess ‘Rautaruukki Oy 2-13 mm ‘RAEX 220C laser (oow par of Ruukki) Ror HRPO RAEK 250 laser Se panne oisnaetnater! + Low variability in composition Lyaohtersbaaa + Cate ling ad leveling techology o ee nia el stress BAEK 3BIMC leer ik miking ony * No painting/stampings SSAB-Rotioge 18-16am Domex 220 ¥P No ned for pci LP prods ice ei (Swen Se)” tor HPO Domex 240 ¥P ds eaten ar god et ven omen 250 YP steines beter hie s-cled spectal ‘Dome 310 XP sts for ae eating ‘ Domex 30 XP lcd Domex: c Bare 390 + Low 5a snes of mcs net martngs oly * No paitiogitamgigs -Acuntely conto tetmamechenicl ot rong proves Thyssen Sut HR and HRPO 438 Theamocet | oe $5 Temes 1 + Saale for plasma and se cating $ Themecat * Ingove pty trough modern, Ss mete renthay SB Re + chs tolerance ox Composition eee + S002% and P< 0005% esa wn *sie003% La “Close ere on mechanic poptis 7Q385-1e + Low ria eases df pel masass Uc rice, holding tempts in PASSOLC sors ranges Guing rong ts well sing ode cold ed wan stig chines siestnt HR stuaser 220 (now pa of are) 2-127 mm, or Sider 240 * Suita for asa nd ser cating RPO Sidlaser 380 Renita 2-63 mm Sider 420 «* Tighter tolerances on dimensions and faess + Reduod seater in mechanical popes Brkish See 2.5mm Lassie HRA (170 N/m? YS) (aow pa of Com) HR or HRDO 2s + 50.00% eabnies: ue apearnce eae ‘ast themnal cutting, good edge, ease of ee valine laser beam has a near-Gaussian mode, and the implications of this difference in beam mode on cutting is yet to be determined.12 J. Laser Appl, Vol. 18, No. 2, May 2006 3. CO lasers Again, compared to the CO, laser, the lower wavelength of the CO laser (Sym) offers better energy absorption, smaller spot size and beam delivery using optical fibers, While encouraging results were obtained with stainless ste! and aluminum alloys, results of cutting trials on mild steel up to 6 mm in thickness using an oxygen-assisted fast axial flow CO laser showed 15%-50% lower cutting speeds compared to conventional CO, cutting st the same power levels." The authors attributed this difference to the larger spot size achieved with the CO laser in the trials due to faulty optics or poor beam quality. The CO laser beam was also found to be very sensitive to moisture in the beam delivery system which caused significant degradation in laser power, A lot more work is needed before CO lasers can be used for cutting thick steel plates in industrial production, ACKNOWLEDGMENTS ‘The author would like to acknowledge significant contri- bations from a number of current and former colleagues at the various Mittal Steel USA plate manufacturing locations. Lenny Salvage and Sam Lawrence performed the electric probe microanalysis. The author is also grateful to personnel in the following organizations that assisted this effort by con- ducting laser cutting trials—Caterpillar Technical Center, La- ser Precision, TrumpfUSA, PRC Laser, W.A. Whitney, Inc. Special thanks to Mike Byrne and Rick Bodnar for review of the manuscript and insightful comments. 'LIA Handbook of Laser Materials Processing, eited by J. F. Reedy (Laser Institue of Americ, 2001), Chap. 12, pp. 425-453. 31. 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