As reported by SME in their article “Ultra-High-Power Fiber Lasers Change the Competitive Landscape of Cutting,” the introduction of kilowatt-level fiber lasers in the early 2000s has revolutionized laser cutting, transforming it from a niche method to a mainstream fabrication process. Fiber lasers are now the dominant technology in the laser cutting of sheet metals due to their ease of integration, reliability, low maintenance, and lower capital and operating costs.
In recent years, the adoption of ultra-high-power (UHP) fiber lasers, ranging from 10 to 40 kW, has surged in the fabrication industry. Observations from FABTECH’s exhibition floors and educational seminars reveal a dramatic increase in maximum cutting power, from 6 kW in 2016 to 40 kW in 2022. This sevenfold increase over six years highlights the rapid pace of UHP laser development. Notable advancements include the introduction of 50-kW fiber lasers and high-efficiency UHP fiber lasers with electrical efficiencies exceeding 50%, offering significant energy savings.
The feasibility of the UHP cutting trend is due to three key developments: reduced cost per kW-power of fiber lasers, availability of cutting heads capable of handling ultra-high laser power, and improved application engineering knowledge for high-power laser cutting. Increased laser power leads to faster cutting speeds, reducing operating costs and cost-per-part. For instance, the cutting speed for most stainless steel thicknesses more than quadruples when power increases from 6 kW to 15 kW, using the same assist gas pressure and nozzle size.
UHP lasers also enable dross-free cutting of thick carbon and stainless steel with high-pressure air instead of more expensive nitrogen, offering faster cutting speeds. For example, cutting 16-mm thick carbon steel with a 30-kW laser achieves speeds greater than 9 m/min with air-assist gas, compared to 2 m/min with oxygen.
Using nitrogen-assist gas, the cutting speed for 10-mm thick stainless steel increases from 2 m/min at 6 kW to over 12 m/min at 15 kW, resulting in a two- to threefold drop in cost-per-part. Additionally, the cost of laser cutting systems does not double with increased productivity, as the cost per kilowatt decreases with higher laser power and is absorbed in the overall machine tool cost.
UHP fiber lasers have made laser cutting more competitive compared to mechanical methods like punching, offering flexibility, lack of tool wear, non-contact cutting, and the ability to cut intricate thin walls. While punching is advantageous for mass manufacturing simple geometries, the demand for flexibility in fabrication has shifted the cost consideration in favor of high-speed UHP laser cutting.
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Article with all rights reserved, courtesy of sme.org.
