Laser Cutting Metallic Components Using Pulsed Beam Sublimation
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Solution Overview
Problem
Laser beam cutting of metallic components often results in significant heating, leading to distortion, deformation, or incomplete separation, especially at the start or end of cuts, due to high energy input, which can damage the component and affect the quality of the cut seam.
Innovation Solution
A method involving multiple scans of the laser beam along the cutting line with overlapping paths, gradually deepening the cutting gap through sublimation, using a pulsed laser with a frequency of 1 kHz to 50 kHz and short pulse lengths, and adjusting parameters to minimize heat input and prevent shadowing, allowing for precise control of the cutting process without the need for protective gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high energy input laser beam is used for cutting, then cutting speed is improved, but thermal damage and distortion increase
Solution Approach 1:
The patent applies periodic action by using pulsed laser radiation instead of continuous laser beam. The laser emits short pulses with durations of 1-100 ns at repetition rates of 1 kHz to 1 MHz, creating periodic heating cycles that allow heat dissipation between pulses. This prevents excessive heat accumulation and thermal damage while maintaining cutting effectiveness through repeated ablation cycles.
Solution Approach 2:
The patent employs parameter changes by systematically adjusting laser pulse characteristics including duration (1-100 ns), repetition rate (1 kHz - 1 MHz), and energy per pulse. These parameter variations enable optimization of the ablation process to achieve high cutting speeds while controlling thermal input to prevent distortion and damage to the workpiece.
2Ease of manufacture
If continuous laser beam is used for cutting, then processing is simpler, but heat accumulation and deformation occur
Solution Approach 1:
The patent replaces continuous laser beam with periodic pulsed radiation, where the laser operates in discrete pulses rather than continuously. This periodic action fundamentally changes the thermal profile from continuous heating to cyclic heating with cooling intervals, eliminating heat accumulation and deformation while maintaining process simplicity through automated pulse control.
3Productivity
If high power density is applied, then material removal is faster, but melting and dross formation increase
Solution Approach 1:
The patent exploits phase transitions by using ultra-short laser pulses (1-100 ns) that deliver energy faster than heat can conduct into the material, causing direct sublimation or rapid vaporization of metal. This phase transition from solid to gas occurs before significant heating of surrounding material, enabling fast material removal without melting or dross formation, thus maintaining high cut quality.
Solution Approach 2:
The patent replaces thermal-mechanical cutting processes with direct laser-induced phase transition. Instead of relying on prolonged thermal heating that causes melting and mechanical ejection of molten material, the ultra-short pulses directly sublimate material through optical energy absorption, eliminating the melting stage and associated quality issues.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method achieves high cutting quality with minimal damage to the cut seam areas, reduces thermal impact on the component, and prevents damage to coatings or paintwork, enabling precise separation with low energy input and efficient emission management.
Implementation Method 1
the focus area is guided several times along the cutting line or over the cutting line or cutting contour... the depth of the cutting gap is increased with each traversal... through sublimation
Implementation Method 2
using a pulsed laser with a frequency of 1 kHz to 50 kHz and short pulse lengths... minimize heat input
Data Source
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Figure 5
AI summary
Laser cutting method comprises enlarging the depth of the cutting gap during each carrying away of the cutting line. An independent claim is also included for a device for laser cutting of a metallic component (1).